Disc Springs for High-Force Applications in Limited Space
When designing mechanical systems where space is limited but high force is required, Disc Springs (also known as Belleville Springs) are often the ideal solution. These compact, high-performance springs offer significant force generation in a small footprint, making them perfect for high-load applications in industries ranging from aerospace to automotive.
At Dongguan Sango Hardware Fasteners Co., Ltd., we specialize in the manufacturing of precision disc springs designed for force storage, shock absorption, and load-bearing applications in compact mechanical systems.
1. What Is a Disc Spring?
A Disc Spring is a conical-shaped spring that compresses under load to provide high force resistance. Unlike traditional coil springs, disc springs have a small height and large load capacity, making them ideal for space-constrained systems where high-performance spring action is needed.
🔩 Key Features:
- Compact design for high-force applications
- Variable spring rate—force increases exponentially with compression
- High load capacity in a small space
- Multiple springs can be stacked for increased load and force
- Durability under repeated compression and expansion cycles
2. Types of Disc Springs
🔹 Standard Disc Spring
- Simple, conical shape that provides high force per unit of height
- Ideal for heavy-duty machinery, automotive components, and industrial valves
🔹 Stacked Disc Springs
- Multiple discs stacked together to increase overall force capacity
- Used in high-load applications such as presses, suspension systems, and clutch mechanisms
🔹 Belleville Washers
- A form of disc spring with a thinner profile, used for seating pressure or load balancing
- Common in electrical contacts, bolted joints, and hydraulic systems
🔹 Double-Concave Disc Spring
- A double-curved disc spring used in precision instruments for smooth force control
- Ideal for mechanical testing devices and load cells
🔹 Custom Disc Springs
- Custom-designed springs for specific load, size, and material requirements
- Perfect for aerospace, automotive, and medical devices
3. Applications of Disc Springs
Disc springs are integral in high-performance applications requiring compact space and high load-bearing capacity:
- 🛠 Heavy machinery (presses, stamping tools)
- 🚗 Automotive suspension systems, clutch mechanisms
- ✈️ Aerospace landing gear, actuator mechanisms
- 🧰 Industrial valves and hydraulic systems
- 📦 Packing and compression mechanisms
- 🧪 Medical equipment and devices (catheters, implants)
They are ideal for use in situations where spring rate consistency and high fatigue resistance are critical.
4. Material and Finish Options
| Material | Features | Best Use Cases |
|---|---|---|
| Stainless Steel | Corrosion-resistant, high tensile strength | Aerospace, medical equipment |
| Alloy Steel | Strong, durable, impact-resistant | Heavy-duty machinery, suspension |
| Carbon Steel | Cost-effective, high load capacity | Industrial valves, press machinery |
| Phosphor Bronze | High fatigue resistance, low friction | Electrical systems, low-load parts |
Finish options:
- Passivation for stainless steel
- Zinc coating for corrosion protection
- Powder coating for aesthetic finishes and wear resistance
- Black oxide or phosphate for added protection in industrial environments
5. Customization from Sango Hardware
We provide:
- 📏 Spring sizes: Inner diameter from 5mm to 200mm, custom lengths
- 📐 Thickness: Customizable thickness for varying load requirements
- ⚙️ Material types: Stainless steel, alloy steel, carbon steel, phosphor bronze
- 🧩 Custom designs: Stacked, double concave, Belleville washers, and custom geometries
- 🔩 Surface treatments: Zinc plating, passivation, powder coating, black oxide
We also offer CAD models, load testing reports, and OEM solutions to ensure the perfect fit for your application.
6. Case Study: Disc Springs in High-Pressure Valve Systems
Client: Global valve manufacturer for oil and gas systems
Problem: Existing valve springs were not providing enough force resistance under high-pressure conditions
Sango Solution:
- Supplied stacked disc springs with custom thickness and tensile strength
- Material: Alloy steel for high load capacity and fatigue resistance
- Delivered with force load testing and performance guarantee
Result:
- Increased valve performance by 30% under high pressure
- Reduced failure rate and maintenance costs by 40%
- Client implemented the solution in all high-pressure valve designs
7. Why Choose Sango Hardware for Disc Springs?
🏭 Precision Manufacturing
- CNC winding, heat treatment, and testing for optimal spring performance
🧪 Quality Control
- Tensile strength, fatigue resistance, dimensional accuracy tested
📐 Custom Engineering Support
- Tailored to fit load specifications, material requirements, and spring configurations
📦 OEM/Export-Ready
- RoHS, REACH compliance, English documentation, bulk or retail packaging
8. Conclusion: High Force in a Compact Design
Disc Springs provide reliable, high-load force control in space-constrained applications. Whether you're designing a press system, automotive suspension, or hydraulic mechanism, disc springs offer the compact performance and durability you need for heavy-duty applications.
Contact Dongguan Sango Hardware Fasteners Co., Ltd. today to find out how our disc springs can improve your mechanical systems and performance.