Compression Springs in Manufacturing: 5 Machine Failures You Can Prevent Today

Fig. 1 A picture of a Compression Spring

In CNC systems and automated equipment, machine failure rarely starts with a loud bang. It begins with something quieter: a drifting axis, a stalled actuator, or inconsistent pressure in a tool head. Often, the underlying cause is force instability, and behind that? A worn or improperly specified compression spring.

These small, coiled components play an outsized role in industrial reliability. They manage loads, absorb shock, reset motion, and protect precision assemblies from wear. But when engineers treat springs as an afterthought—selecting based on rough dimensions rather than exact force requirements—performance declines fast.

Across robotics, actuators, tool changers, and high-speed production lines, improper spring selection contributes to downtime that could have been avoided. This guide outlines five common machine failures that come from poor spring performance. And shows how a better understanding and specification of compression springs, torsion springs, and constant force springs can help protect your equipment from costly interruptions.

Top Failure Points Caused by Bad Springs

Fig. 2 A picture of excessive spring compression effects

Machine failure linked to springs isn’t rare—it’s often just misdiagnosed. From over-compression to material fatigue, the following five issues make up the lion’s share of avoidable downtime.

1. Spring Fatigue: How Long Do They Last?

Every helical spring has a limit. Over time, cycling wears it down. Tiny fractures form, tension drops, and components start to misalign or underperform. In high-cycle equipment, that decline can happen sooner than you think, especially when compression springs aren’t rated for the loads they’re handling.

Consider a small compression spring inside a pneumatic gripper. With every open-close cycle, it compresses and releases. Multiply that by hundreds or thousands of activations a day, and material fatigue becomes a real concern.

If you haven’t calculated the spring constant or verified force limits using a spring constant calculator, the spring may already be nearing the end of its useful life.

Fix it early:

Use compression spring calculators to estimate fatigue limits. In demanding environments, go with stainless steel springs, wave springs, or heavy-duty compression springs. And if your setup is unique, lean into custom springs designed specifically for your machine’s cycle rate and force requirements.

Prevent spring fatigue with high-cycle industrial compression springs—built for the long haul.

2. Mis-sized Springs: Wrong Force or Fit

Two coil springs may look nearly identical, but behave entirely differently. One could exert twice the force of the other. This is where trouble begins.

An underpowered spring might compress too easily, failing to maintain proper contact. An overpowered one might resist motion, cause binding, or stress other components. And using a generic compression spring by size, just because it “almost fits”—is a gamble engineers can't afford.

In critical components like linear actuators or indexing mechanisms, even slight mismatches in spring design can result in jerky motion or inconsistent pressure.

Fix it early:

Stop guessing. Measure precisely—outer diameter, free length, wire diameter—and verify specs using a spring finder or a compression spring formula. Need precision or unusual geometry? Choose custom compression springs over stock approximations. Trusted compression springs suppliers often offer both in-stock and made-to-spec options.

3. Over-Compression: Crushing the Spring

A compression spring is only as good as the space it operates in. Compress it beyond its solid height—the point where all coils are touching—and you risk total deformation. This can permanently shorten the spring, reduce its force output, or cause adjacent components to seize or misalign.

This happens frequently in automotive repairs involving compressing springs on struts or in industrial presses where the spring compression tool isn’t used correctly.

Fix it early:

Know your limits. Never allow the compressed spring to reach full coil bind. If the application requires long travel, consider conical compression springs, long compression springs, or flanged compression springs that accommodate variable loads. If you’re using a spring compression tool, make sure it’s rated for your specific spring size and strength.

4. Wrong Spring Type for the Motion

Not all motion is linear. And not every load demands a compression spring. Sometimes, the issue isn’t with the spring—it’s that the wrong type of spring was selected in the first place.

Rotating components? You probably need a torsion spring. Counterbalancing motion? Look into a constant force spring. Stretch-and-return mechanisms? An extension spring is your best bet.

Using a compression spring where a torsion spring belongs doesn’t just reduce performance—it can cause real mechanical damage, especially in systems with precise rotational timing or torque requirements.

Fix it early:

Map your motion—are you pushing, pulling, or twisting? Choose torsion springs, extension springs, or constant force springs accordingly. For specialized motion, like cable retraction or tool return systems, a constant force torsion spring custom manufacturer can help you design for consistency and repeatability.

5. Temperature and Environmental Stress

Extreme environments are where metal springs get tested. In marine equipment, moisture corrodes unprotected steel springs. In high-heat zones, like ovens or die-casting machinery, thermal expansion affects spring behavior and alters the spring constant.

Even stainless compression springs aren’t immune if you use the wrong alloy grade. Add in chemical exposure or high-humidity conditions, and you’re looking at premature failure, long before the cycle limit is reached.

Fix it early:

Select material based on more than just the application load. Use stainless compression springs with proper coatings for washdown or corrosive environments. In heat-intensive processes, talk to an industrial spring supplier about performance alloys.

Compact systems? Flat spiral constant force springs offer reliable force and corrosion resistance in tight spaces.

How the Right Spring Solves These Issues

Choosing the right spring is less about size alone and more about behavior. Whether it’s a compression spring, torsion spring, or extension spring, the way a spring performs under stress, temperature, and load cycles matters as much as its shape.

An undersized spring might compress too early and deliver inconsistent force. One made from the wrong material might corrode in a washdown environment or lose tension under high heat. And a poorly matched spring might function—but only just—until vibration, misalignment, or overtravel destroys it entirely.

With correct selection, though, springs become high-reliability components. A properly rated compression spring maintains precise pressure through thousands or millions of cycles. A high-quality stainless steel spring resists environmental damage without losing elasticity. A carefully chosen constant force spring delivers smooth, repeatable motion across its full range.

Here's what to look for when choosing a spring:

Match spring rate to system load: Use a spring constant calculator to balance applied force with required deflection.

Design for fatigue life: If your system runs continuously, consider compression springs heavy-duty or wave springs with enhanced fatigue resistance.

Choose the right material: Use stainless compression springs in corrosive or wet environments, and ask about surface treatments or coatings when needed.

Optimize geometry: For space-limited assemblies, miniature springs, flat springs, or conical compression springs provide reliable force in compact designs.

Explore customization: Custom coil springs allow for optimized pitch, length, and diameter for one-off or OEM systems.

When engineered correctly, springs not only reduce wear on surrounding parts but also extend machine life. Instead of becoming the weakest link, they reinforce your system's reliability.

Order from stock or get fast turnaround on custom sizes for your machinery needs.

Compression vs Tension vs Constant Force Springs

Every motion type—push, pull, rotate—requires a different kind of spring. That’s why choosing based on motion behavior is often more critical than choosing based on appearance or rough measurements.

Compression Springs

Fig. 3 A picture of a Compression Spring

What they do:

Compression springs resist force when compressed and return to their original shape when the force is removed. They’re the most widely used coil springs in industrial design.

Where they work best:

Load-bearing equipment

Valve assemblies

CNC actuators

Pressure regulators

Why they matter:

They manage shock, store energy, and stabilize motion in linear systems. Whether you're dealing with big compression springs or small compression springs, sizing to force and stroke distance is essential.

Common variants:

Helical compression springs

Long compression springs

Heavy-duty compression springs

Extension Springs

Fig. 4 A picture of an Extension Spring

What they do:

Extension springs stretch under load and pull components back together.

Where they work best:

Garage doors

Agricultural equipment

Tension-based fixtures

Why they matter:

When pulling forces need to be balanced or stored—such as in lifting or return mechanisms—tension springs offer the best performance.

Custom options include:

Extension springs with hook ends

Long length extension springs

Heavy-duty extension springs

Torsion Springs

Fig. 5 A picture of a Torsion Spring

What they do:

Torsion springs apply torque as they rotate around an axis. Unlike compression or tension types, they work in twisting motion.

Where they work best:

Hinges

Levers

Rotary tools

Camera shutters

Why they matter:

When you need force around a pivot or shaft, torsion springs provide controlled resistance and return.

Special considerations:

Use a torsion spring calculator for torque-to-angle conversion

Consider double torsion springs for bidirectional load

Constant Force Springs

Fig. 6 A picture of Constant Force Springs

What they do:

Constant force springs exert nearly uniform force across their range of motion. They’re usually made from pre-stressed flat strips.

Where they work best:

Cable retractors

Medical devices

Counterbalance systems

LED lighting arms

Why they matter:

They maintain steady force without the variability found in traditional coil springs, which makes them ideal for delicate, precise tasks.

Advanced options include:

Flat spiral constant force springs

Stainless steel coil springs for machinery

When to switch spring types:

If motion is linear with push force, use compression springs

If motion is linear with pull force, use extension springs

If motion is rotational, use torsion springs

If motion needs a steady, smooth force, use constant force springs

When in doubt, review your motion path, available space, and environmental conditions. Then, consult with a spring supplier or spring manufacturer near me to choose the ideal spring type. Don’t forget to leverage digital tools like a spring finder or spring calculator to streamline the selection process.

Final Thoughts

In industrial design, springs are rarely front and center, but they’re often the first to fail if misunderstood. Choosing the wrong compression spring, ignoring force requirements, or pushing environmental limits adds up quickly in real-world downtime and damage.

Whether you’re sourcing compression springs near me, browsing compression springs Home Depot, or evaluating suppliers for heavy-duty compression springs, the goal stays the same: consistent, reliable force for the system's life.

Use the tools. Work with trusted spring suppliers. And when your project calls for it, invest in custom springs that do exactly what your system demands.

Reduce failure, improve uptime. At JLCMC, we offer a wide range of reliable compression springs for your machining needs. Please give us a call today, and we shall be more than happy to help.

FAQS

What are the failure modes of compression springs?

Compression springs fail due to fatigue, over-compression, corrosion, or improper sizing. Over time, the compression of springs without proper stress relief or surface treatment causes cracks or loss of force.

Using a spring constant calculator and specifying from trusted compression spring manufacturers helps prevent this.

What are the spring failures?

All springs—coil springs, torsion springs, and extension springs—can fail due to stress overload, poor material choice, or misapplication.

Fractures, permanent deformation, and loss of elasticity are common symptoms.

What are four uses of compressed springs in everyday life?

Ballpoint pens: miniature springs

Car suspensions: heavy-duty coil springs

Adjustable chairs: small coil springs

Industrial tools: stainless compression springs

What are the failure modes of coil springs?

Coil springs, especially helical compression springs, fail from overloading, corrosion, misalignment, or fatigue.

Preventing these failures involves proper sizing, routine checks, and choosing the correct material for the operating environment.

Bibliography / References

• Deanza. "Springs." De Anza College - Tops in Transfer. Accessed June 17, 2025. https://www.deanza.edu/dmt/documents/books/egd_lamit/EGD_Chapter_18.pdf.
• Farnell. "Compression springs." Welcome to Farnell Global | Global Electronic Component Distributor. Accessed June 17, 2025. https://www.farnell.com/datasheets/1684468.pdf.
• Leespring. "constant Force Spring Series.". Accessed June 17, 2025. https://www.leespring.com/sites/default/files/2021-02/constant-force-lee-spring-us.pdf.
• Mrspring. "Extension Spring Design." Just a Moment... Accessed June 17, 2025. https://www.mrspring.com/wp-content/uploads/2021/02/Extension-Spring-Design-Info.pdf.
• Zhu, Youli, Yanli Wang, and Yuanlin Huang. "Failure analysis of a helical compression spring for a heavy vehicle’s suspension system." Failure Analysis, Accident Investigation, Traffic Reconstruction, Fire Investigation, Expert Witness Services, Training | UTC Singapore. Accessed June 16, 2025. https://ut.sg/Failure-analysis-spring.pdf.