Wave Springs

Wave springs are compression springs made from flat wire coiled into a sinusoidal, wave-like pattern designed to provide the same force as a traditional coil spring while occupying significantly less axial space, often up to 50% less. This compact design makes them an ideal solution for applications where space and weight are critical constraints.
Design and Function
Wave springs function by bending, not torsion, when a compressive load is applied. The force-deflection relationship is created by the flattening of the waves.
Axial Space Reduction: The primary advantage is the ability to produce a specific load with a much lower operating height compared to round wire coil springs.
Predictable Loading: Wave springs offer accurate and predictable force characteristics over their working range, allowing for precise control in various applications.
Uniform Force Distribution: Their design ensures an even distribution of force, which is particularly beneficial in sealing applications where uniform rotational pressure is required over 360°.
Types:
Single-Turn: Best for applications with short deflections and low-to-medium forces, often used for bearing preloading or tolerance take-up.
Multi-Turn (Crest-to-Crest): Replaces coil springs in applications needing larger deflections and can accommodate a wide range of forces and diameters.
Nested: Consists of multiple waves within larger ones, coiled in parallel to increase load capacity significantly, often replacing a stack of Belleville washers in high-force static applications.
Materials
Material selection is critical for performance and depends on the operating environment and required cycle life.
Carbon Steel (SAE 1070-1090): A general-purpose, economical choice with high strength and fatigue resistance, suitable for high-stress applications in non-corrosive environments.
Stainless Steel (e.g., Type 302, 316, 17-7PH): Offers excellent corrosion and heat resistance, making it suitable for medical, marine, or aerospace applications.
Alloy Steels (e.g., Chrome Silicon, Chrome Vanadium): These materials provide superior strength, toughness, and fatigue resistance for heavy-duty applications.
Exotic Alloys (e.g., Inconel, Elgiloy, Beryllium Copper): Used in extreme environments (high temperature, cryogenic, or highly corrosive) or where non-magnetic properties or electrical conductivity are needed.
Common Applications
Due to their ability to save space and provide predictable loading, wave springs are used in a wide array of industries.
Automotive Industry: Used in transmission systems, clutches, braking systems, and seat mechanisms where space and weight savings are crucial.
Medical Devices: Employed in surgical instruments, infusion pumps, and implants where precise load control and compact size are essential.
Industrial Equipment: Found in pumps, valves, actuators, and mechanical seals to provide consistent force and durability in demanding environments.
Aerospace: Used in flight control mechanisms and avionic systems that require reliability under extreme conditions and weight constraints.
Electronics: Provide reliable contact force in connectors, switches, and battery contacts within compact electronic devices.