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Case Studies


The Problem

A switch manufacturer contacted Advanex because the local spring maker they were working with was unable to produce springs that met the customer’s design specifications. Advanex offered support despite the fact that the springs they were using were made by a competitor. The customer had calculated the spring by themselves and had the springs produced by a local spring maker but they were over stressed and ineffective. They tried to use the Advanex design software on the website but needed specialist knowledge, so they contacted the Advanex support centre.

The Solution

Advanex were able to offer superior services and knowledge to meet a specific challenge. This was achieved by:

  • Rapid prototyping and testing
  • Quick and helpful correspondence
  • Knowledge and technical ability

The customer required a functioning torsion spring for use in a new joy stick. The customer requested that Advanex design and develop a spring that would repeatedly work through the full range of movement required.

To strengthen the customer’s relationship with Advanex, we arranged for the customer’s engineers and ours to communicate directly due to the complex nature of the project. After their discussion, the engineer at the Koriyama prototype factory designed a spring that was, in theory, up to the task and sent the drawings to the customer.

Using a numerical control multi forming machine in the prototype factory, they then produced a sample with more coils to reduce the fluctuation of stress and avoid spring setting and adjusted the leg angles to give the customer’s required torque levels and aid durability.

In all, five prototypes of the spring were produced. All communication was done via telephone calls and e-mail exchanges with the customer, who appreciated the rapid response from Advanex. During this development the customer then order a compression spring, which further demonstrated their faith in Advanex’s capabilities.

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Torsion spring

Forming Method

Numerical control multi forming

Location Japan

Switch maker


Joy stick




6 months after initial request


Work through full range of joy stick motion


Mass production, fast and effective design

Customers Benefit

To remain competitive