Components that make your products work

New Design Development

The Right Place at the Right Time

There is a way to manufacture the precise components your products need without making mistakes and without wasting time.

That’s what we do!

We enter your process as early as you let us and we make sure you get what you want while ensuring you don’t lose time going down ineffective paths. We make new design development painless and seamless. It's as simple as sharing application information and requirements with us and we take it from there.

Our design engineers will take fit, form and function into consideration and then design a new component. It's all about determining what's the best process to make it work and the most cost effective way of doing it. All along the way we look for every possible opportunity to improve your component and bottom line, like:

  • Determining tolerances to meet specs
  • Choosing optimal production material
  • Reducing cost and secondary operations
  • Reducing stress
  • Improving cycle life

Case Study A -- Two Springs Into One

The Challenge

One of our customers presented us with this request: Combine two compression springs into one. Their component was designed to have the first spring work inside a second, larger spring. The unit was time consuming to assemble, and the customer was looking for a solution to reduce that assembly time.

Design Criteria

  • Fits-over spec (one end only)
  • Fits-in spec
  • Load 1 @ length 1
  • Load 2 @ length 2
  • Acceptable stress

The Solution

Design one single spring for ease of assembly and complete the task of both springs. WCS Industries' engineers started with the outer spring design first. Using a standard compression spring, we made sure the spring met the loads and fits-in spec. We transitioned the outer spring to the inner spring using a conical design to meet the fits-over spec on the small end of the conical spring. We made a number of prototypes for testing, and the end result was a single spring that met customer requirements and ultimately saved valuable time during the assembly process of the customer's single unit.


Case Study B -- Eliminating Excess

The Challenge

A prospective customer approached us with an assembled component looking for cost reduction. What they had consisted of a machined part and hobbed gear which required brazing in a furnace in order to join the two pieces together.

Design Criteria

  • Fit into existing space limitation of assembly
  • Reduce costs
  • Increase strength
  • Eliminate failures

The Solution

Working through the dimensional requirements and tolerances our engineers proposed a one piece solution. The Part is now headed and machined to add the groove. Significant savings were realized by reducing the number of items to manage, reducing the assembly cost and increasing the production rate.