Flat Wire

Custom Flat Wire – Flat Springs, Clips, Brackets….Plus
by Forward Metal Craft Since 1978

Flat wire can be formed to any shape desired to your specification. Flat springs, flat wire brackets, flat wire clips are all within our capabilities. Our high volume capacity creates Forward’s long run production advantage providing cost-saving economies for our customers. Our custom wire forming and fourslide stamping expertise yields precision and consistency throughout the entire production cycle. Our capabilities include:

  • Flat wire .001″ thick to .125″ strip material thickness, up to 2 1/2″ wide
  • State-of-the-art wire forming machinery
  • Wire form tooling capabilities from our in-house tool & die shop. We can be in production without the delays involved in outside maintenance
  • Fourslide stamping with presses ranging from 1/2 ton to 75 tons
  • ISO 9001: 2015 certified commitment to continuous improvement
  • Prototype to production volumes
  • Complete list of materials used
  • On-time delivery

Some examples of our flat wire products found above include components for the furniture industry including partition clips, brackets, and wiring clips for holding office partitions in place. Other parts have been manufactured for the automotive industry including fuel-tank components, air cylinder clamps, wiper-arm extensions, copper switches for electric mirrors, and flat springs for holding car mirrors. Also seating cushion springs and clips for holding seat upholstery are featured. In the medical field, flat springs have been manufactured that compress razor blades in a complex application.

Thank You for considering Forward Metal Craft for your project for custom flat wire project.

The Many Uses of Flat Springs

By definition, flat springs are flat strips of material that when deflected by an outside load is capable of storing and releasing energy. These small components are made of stamped metal and function very similar to a standard spring by controlling deflection within restricted spaces. However, these springs can also function like a ground or spacer.

Although flat springs can be manufactured with several different materials, these parts are usually made from high carbon steel, nickel alloys, stainless steel, phosphor-bronze or beryllium copper, and the combination of silver and nickel. Based on customer requirements and specific application, flat springs are manufactured in a variety of configurations.

There are two primary categories of flat springs to include leaf and flat coil. While they share many characteristics there are also distinct differences. Both of these flat springs are designed with layers or “leaves” of metal and both must be manufactured precisely and accurately.

Leaf Springs

These flat springs are a critical component specific to suspension often associated with the automotive industry. These springs provide stability but also minimize wear and tear on other parts. In addition to leaf springs being used in automobile design, they are an essential component for repair, often used on steering and drive axles.

Usually, these flat springs are made from lighter weight material. Leaf springs also come in three primary types to include:

  • Parabolic – These flat springs are designed with tapered or stacked layers of “leaves”.
  • Mono – In this case, the springs are made from just one steel plate that is uniformly tapered from the center to the end of each spring.
  • Multi – Flat springs of this kind attach to an automobile via a spring eye located on both sides of the spring.

Flat Coil Springs

The other category of flat springs is the flat coil, which is also commonly used in the automotive industry. These springs are used along with a counterweight as a means of controlling valve action. As an example, when these flat springs are used in an automobile’s exhaust system, they are wound into the required configuration to provide tension while absorbing shock. However, these flat springs are also used for support in seating.

Other Industries

In addition to the automotive industry, flat springs are key components for many other industries such as aerospace, agricultural, computer, electrical, firearms, lawn and garden, medical, sporting goods, telecommunications, and many others.