Torsion Springs: A Complete Guide toDesign, Applications, and Manufacturing

Torsion springs play a critical role in countless mechanical systems across industries, from automotive and aerospace to medical devices and industrial equipment. As one of the most versatile spring types, torsion springs are engineered to store and release rotational energy with precision and reliability.

At Southern Precision Spring, we specialize in manufacturing high-quality custom torsion springs built to exact specifications. In this guide, we’ll break down how torsion springs work, where they’re used, material options, and what to consider when sourcing a custom torsion spring manufacturer.

What Are Torsion Springs?

A torsion spring is a mechanical spring that works by twisting rather than compressing or extending. When force is applied to the spring’s legs, it stores energy by resisting rotational movement. Once the force is released, the spring returns to its original position, delivering controlled torque.

Unlike compression or extension springs, torsion springs are designed to operate through angular deflection. This makes them ideal for applications requiring precise rotational force and repeatable motion.

Key characteristics of torsion springs include:

• Resistance to twisting force (torque)

• Ability to store rotational energy

• Long service life when properly designed

• Customizable leg lengths, angles, and coil diameter

How Do Torsion Springs Work?

Torsion springs function by applying torque around a central axis. As the spring’s legs rotate, internal stress builds within the coils. This stored energy is released as the spring attempts to return to its original shape.

Important performance factors include:

• Torque output

• Angular deflection

• Wire diameter

• Inside diameter

• Leg configuration

Precision manufacturing is essential, as even small variations can significantly affect performance, fatigue life, and safety.

Common Applications of Torsion Springs

Torsion springs are used in a wide range of industries due to their versatility and durability.

Industrial & Manufacturing:

• Conveyor systems

• Machinery guards

• Hinges and levers

• Automation equipment

Automotive:

• Seat mechanisms

• Door handles

• Hood and trunk components

Medical Devices:

• Surgical instruments

• Diagnostic equipment

• Precision motion components

Consumer Products:

• Garage doors

• Clipboards

• Hinged lids and closures

Each application requires unique design considerations, which is why many OEMs rely on custom torsion spring manufacturers rather than off-the-shelf parts.

Materials Used in Torsion Spring Manufacturing

Selecting the right material is critical to spring performance, durability, and environmental resistance.

Common torsion spring materials include:

• Music Wire (ASTM A228): High tensile strength, ideal for general applications

• Stainless Steel: Corrosion resistance for medical and outdoor use

• Oil-Tempered Wire: Excellent fatigue resistance

• Chrome Silicon: High-stress and high-temperature environments

• Phosphor Bronze: Electrical conductivity and corrosion resistance

At SP Spring, we help customers choose the best material based on load requirements, operating environment, and lifecycle expectations.

Custom Torsion Springs vs. Stock Springs

While stock torsion springs may work for basic applications, many industries require custom solutions for optimal performance and safety.

Benefits of Custom Torsion Springs:

• Precise torque control

• Improved fatigue life

• Better fit and function

• Reduced maintenance and failure risk

Custom manufacturing allows engineers to fine-tune every aspect of the spring, from wire size to leg orientation, ensuring consistent performance in demanding applications.

Design Considerations for Torsion Springs

When designing or sourcing a torsion spring, consider the following factors:

• Required torque and rotation angle

• Space constraints

• Operating temperature

• Environmental exposure (moisture, chemicals)

• Expected cycle life

Working with an experienced spring manufacturer early in the design process can reduce costs, improve efficiency, and prevent premature failure.

Why Choose SP Spring for Torsion Springs?

At Southern Precision Spring, we combine advanced manufacturing capabilities with decades of spring engineering expertise. Our team works closely with OEMs, engineers, and procurement professionals to deliver precision-engineered torsion springs that meet exact specifications.

What sets us apart:

• Custom torsion spring manufacturing

• Tight tolerances and consistent quality

• Material expertise across industries

• Fast prototyping and production

• Dedicated engineering support

Whether you need a single prototype or full-scale production, we can be your trusted partner for torsion spring solutions.