Digitization of Spring Manufacturing

Federnfabrik Schmid AG has set itself this ambitious goal. With the support of Innosuisse, the Zurich based medium-sized company was able to rethink and digitize its processes. In doing so, it is breaking with a mechanical approach that has been in place for generations. This transformation enables it to integrate components that can assess the condition of the springs in real time, representing a minor revolution in this field.

Springs are ubiquitous in our everyday lives and are used in a wide variety of objects such as coffee machines, ballpoint pens, and musical instruments. Albert Enste, CEO of Federnfabrik Schmid SA, emphasizes: "There is hardly a machine that does not contain springs. These act as actuators that provide safety and exert force in objects such as watches, wind turbines, and satellites". Founded in 1912, the company he heads specializes in the supply of high-precision industrial springs. Today, it employs around sixty people and exports around 80% of its production. The springs, which come in various sizes, are made from different metals and alloys.

Although springs are essential components and many objects and applications rely on them to function properly, they have a weak point. Their condition and service life can only be predicted in theory. “The design of conventional springs is based on theoretical approaches, and their operation under real conditions often deviates from these calculations. This means that the spring can fail unexpectedly, damaging the application and resulting in high repair costs,” explains Dr. Ing. Cord Teller, Head of Technical Sales.

Failures, replacement costs, etc. therefore have many consequences for manufacturers. “We realized that spring failure in machines is a major problem for our customers,” confirms Albert Enste. The company is considering expanding its product portfolio and is focusing its attention on the Internet of Things (IoT). “We realized that springs were not integrated into the digital world of machines. That's how we came up with the idea of developing a connected spring,” explains Albert Enste.

The idea was born, but the technical expertise to develop such a project in an SME was lacking. “We needed very specific knowledge in microelectronics,” explains Albert Enste. The company then turned to Innosuisse and sought advice and confirmation from an innovation mentor. In 2021, the company launched an innovation project in collaboration with CSEM. Two years later, the I-Spring prototype was developed.

This compact, independent system is capable of displaying the condition of the spring live on a smartphone or browser-based dashboards. "This sensor-based technology makes it possible to monitor and measure the spring, display its service life and remaining strength, and enable predictive maintenance and real-time monitoring of its condition. It is designed to function throughout the entire service life of a spring," explains Dr. Boris Ouriev, Head of the Innovation Department. Boris Ouriev, Head of the Innovation and Implementation Department at Federnfabrik Schmid AG.

Today, the prototype of the smart spring is ready for use and is being tested on the products of several of the company's customers. The feedback has been positive. For Cord Teller, this is the first step toward transforming the company's business model. "This innovation represents a revolution in the field of springs. It will completely transform our business model and is already changing the perception of our customers and employees.

For Federnfabrik Schmid AG, this step toward digitalization and connectivity is also an opportunity to secure its long-term future. "As a traditional SME, we see innovation as a real opportunity. It not only enables us to diversify our activities and explore new horizons, but also opens the door to new markets. The impact on the company is also significant. We can introduce new products, create jobs, improve our processes, and also have a positive effect on the environment," says Albert Enste.

Author of the article and video created by Johanne Stettler ©Innosuisse.

Many thanks to InnoSuisse and CSEM for their support in this project!