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Why bother with chemistry and electronics when you can get great performance from sturdy, reliable mechanical motion control?While not all hinges use mechanical springs, they're often the go-to choice over fickle gas springs and expensive electronic motion control. Mechanical spring design combines affordability, reliability, and versatility to improve product safety and performance.
There are several types of mechanical springs, each offering distinct benefits and applications. Keep this guide on hand, and you'll have a helpful reference when selecting a spring for your motion control needs.
7 Types of Mechanical Springs & Their Applications
Many motion control applications begin with selecting the right mechanical spring. Spring-loaded mechanism design usually starts with one of these seven concepts:
- Compression
- Extension
- Torsion
- Constant force
- Spring clip
- Belleville
- Volute
1. Compression Springs
This kind of mechanical spring design stores energy or force when compressed. As it expands, it releases energy. Compression springs are wound with spaces between the coils to store specific energy loads.
For example, when you close a lid with a compression spring hinge, it compresses the spring to get more torque to counterbalance the lid. As you open the lid, the energy is released and assists the user in opening the lid easily. Just like that, you can make a 75-lb. lid feel like 5 lbs.
When to use them: Compression springs are not just used for counterbalancing, but also to save space. They can be found in switches, vehicle suspensions, and -- most famously – in jack-in-the-boxes.
2. Extension Springs
Extension springs are the opposite of mechanical compression springs. As you stretch the spring, the force increases.
They are initially wound with a specific level of tension. Most extension springs require significant force to even get them to start to move. There are some exceptions that require 0 initial tension -- they’ll start to immediately spread out when you apply force.
Many extension springs have hooks on the ends. Hooks allow you to attach them to two points and use them to prevent initial separation -- and pull those points back together when they’re separated by the tension.
When to use them: One way extension and compression spring hinges are alike is that they’re capable of counterbalancing. Whether you use compression or extension depends on the application and direction of motion you need.
Extension springs are common in screen door hinges, trampolines, and garage door hinges.
3. Torsion Spring
These are wound similar to extension springs but have legs that come off at different angles. By pushing the legs, you generate clockwise and counterclockwise torque.
A spring-loaded mechanism design can employ torsion springs to store energy from twisting motions and release that energy in opposite motions
When to use them: Engineers use torsion springs on …
- Saloon-style doors
- Ramps for horse trailers, to make them easier to open
- Keyboard mechanisms, for easier up-down motion
4. Constant Force Spring
A constant force mechanical spring hinge will deliver force no matter how far you extend the spring.
Think of the tape measure in your toolbox. A tape measure retracts with the same energy whether it’s a few inches or 5 feet out of the casing. If you used a compression spring instead, it would pull back more aggressively as you tried to extend it.
When to use them: These are ideal for any type of lift mechanism where you have a known weight, such as TV or computer monitor lift mechanisms.
Looking to learn more about motion control? Download our free guide to see how counterbalancing can improve product design.
5. Spring Clip
A spring clip is extremely simple -- just a bar of material either round or rectangular.
If the spring features a round material, the more general term for a spring clip is “wire form.” If a rectangular material is used, it may be called a flat spring (even if it has a form in it). "Flat" refers to the material, not the shape of the spring. You may have also heard of a leaf spring, which is a subcategory of flat springs.
Spring clips are generally U-shaped, but there are exceptions.
More importantly, they absorb energy -- when you bend one, it applies force in the other direction.
When to use them: Diving boards are the classic example of spring clip design. You can also find them in wagons and buggies, car suspensions, and other industrial spring hinges.
6. Belleville Spring
Belleville springs, also called Belleville washers and disc springs, are typically disc-shaped washers with a hole in the middle for bolts to pass through. They offer a specific load and deflection in places where you know your design will sustain wear over time. These springs help components remain in contact with one another by providing compression.
Now for the fun part: You can stack Belleville springs in different ways to alter the force you get out of them. You can stack them in the same direction to increase the spring rate or in different directions to decrease the spring rate, depending on your need.
When to use them: Engineers primarily use Bellevilles in applications that require an extremely high level of force over a small deflection. In many cases, Belleville springs are used to replace coil springs where space is tight.
7. Volute Spring
These are wound into a spiral. When you compress them, they become very compact and flat.
Volute springs resemble the ice cream portion of a soft-serve cone. (OK, maybe that’s a stretch.) When a volute spring is compressed, its smaller coils slide inside its larger coils, shrinking the spring’s length far more than traditional compression springs.
When to use them: Volutes are a less common spring type, but you often can find them in garden shears. Thanks to their high load-bearing capacity, they’re perfect for situations where you need shock absorption.
Choosing Between Types of Mechanical Springs
Mechanical springs come in a wide range of designs, and each type is built to manage motion in a different way. The right choice depends on how the product moves, the amount of force required, and the space available within the design.
Understanding the different types of mechanical springs makes it easier to compare options early in the design process. Taking the time to evaluate each spring's characteristics can help support long-term performance and a better user experience.
FAQs About Types of Mechanical SpringsStill have questions? Here are answers to a few common questions about types of mechanical springs and their role in motion control applications. Q: How do I choose the right mechanical spring for my application?A: Choosing the right mechanical spring starts with understanding how the product is intended to move. The spring should match the motion, the amount of force needed, and the way the product will be used over time. Looking at the entire application instead of a single component often leads to a better design. Q: What's the difference between a mechanical spring and a gas spring?A: Mechanical springs create force through the movement of metal, while gas springs use compressed gas inside a sealed cylinder. Both are used for motion control, but they behave differently throughout their range of motion. The right choice depends on the application. Some products benefit from the simplicity of a mechanical spring, while others require the smooth, controlled movement that a gas spring can provide. Q: How long do mechanical springs typically last?A: Mechanical springs can last for thousands or even millions of cycles when they're designed for the application and used within their intended operating range. Because every application is different, there isn't a single lifespan that applies to every spring. The best way to maximize service life is to match the spring to the product's motion and performance requirements early in the design process. Doing so helps reduce unnecessary stress and supports reliable operation over time. |
Take a Deeper Look at Motion Control
Looking beyond spring selection? Download our free guide for a closer look at motion control and counterbalancing in product design.
[Editor's note: This blog was produced in February 2020 and was updated in July 2026 to reflect current information.]
