Wave Spring End Types: Selecting The Right Configuration

Wave spring end types play a critical role in how the spring interfaces with mating components, directly impacting load distribution, surface contact, and overall application performance. Wave springs are a type of compression spring designed to provide precise load control while reducing space and weight, using a waveform structure that distributes force through bending rather than torsion. Selecting the correct end type helps minimize surface wear and allows the spring to function as intended within the assembly. 

Key factors engineers should evaluate include: 

• Surface condition of mating components 

•  Required load distribution 

•  Clearance within the assembly 

•  Sensitivity of contact surfaces 

•  Assembly and handling conditions 

Evaluating these factors early in the design process helps align spring configuration with application performance. 

Rotor Clip manufactures single-turn and multi-turn wave springs in sizes ranging from 3 mm to 635 mm, with features that can be customized for specific application requirements. Adjustments to turns, wave count, material thickness, radial dimensions, and especially end type allow engineers to optimize performance, improve load distribution, and accommodate mating components. Because wave springs are coiled rather than stamped, many modifications can be implemented without special tooling, making both standard and custom designs efficient to produce. 

Multi-Turn Wave Spring End Types 

Multi-turn wave springs consist of a continuous series of waves along multiple turns, designed to meet a wide range of force and deflection requirements. These springs can be tailored to specific application needs through adjustments to wave count, number of turns, wire thickness, material selection, and end-type configuration, allowing engineers to achieve the required load, travel, and assembly fit. 

Available end types include: 

Plain Ends 

Plain ends are the standard configuration for multi-turn wave springs. The spring terminates at the next wave peak, providing consistent contact with mating surfaces and uniform load distribution across the spring. 

Shim Ends 

Shim ends include additional flat turns or layers at the top and bottom of the spring. These flat sections help distribute load evenly across the spring’s surface, which is particularly useful when the spring interfaces with: 

• Uneven surfaces, such as grooves, holes, or slots in mating components. 

• Soft materials, including plastics, rubbers, or soft metals, where load needs to be spread over a larger area. 

In certain applications, multiple shim layers can be used to affix the spring into a groove or retain it securely on the mating component, providing additional stability. 

Floating Ends 

Floating ends are cut slightly shorter, so the spring’s end does not rest directly on the adjacent wave peak. This design minimizes concentrated contact points, reducing the potential for scratching or surface damage. Floating ends are particularly beneficial for springs with thicker wire cross-sections or applications where mating surfaces are sensitive. 

Single-Turn Wave Spring End Types 

Single-turn wave springs consist of a single turn with multiple waves, providing reliable compression in a compact axial space. They handle low to high thrust loads and are suited for narrow radial walls, low clearances, and assemblies with ball or roller bearings. They can also replace stacked disc springs, simplifying installation and reducing component count. 

These springs are customizable through wave count, wire thickness, bore or rod diameter, material selection, and end-type configuration. Some designs include a “cling in bore” option to center and maintain alignment. Single-turn wave springs deliver consistent load with tighter tolerances than stamped washers or disc springs, and coiling minimizes material waste. 

Available end types include: 

Overlap Ends 

Overlap ends bring one spring end over the other, eliminating gaps. This configuration prevents tangling during handling, ensures smooth mating with the surface, and avoids concentrated stress points that can occur at open ends. 

Gap-Type Ends 

Gap-type ends create a defined space between the ends of the spring. The size of this gap can be controlled to accommodate assembly clearance requirements or specific mating components that must pass through the spring during operation. 

Patented Flat Ends 

Rotor Clip’s patented flat-end design flattens the ends of the spring, removing sharp corners. This allows the spring to sit evenly against the mating surface, reducing wear and protecting bearings. Flat ends are ideal in preload applications or where minimizing surface stress is critical. 

Rotor Clip delivers Application Driven Solutionsᵀᴹ and has extensive experience designing products for applications across nearly every industry. Our engineers provide on-demand support tailored to your needs. For guidance on selecting the right wave spring and end type, contact an engineer today.