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Die Springs vs NitroSprings: What’s the Difference?
DIE SPRINGS VS NITROSPRINGS: WHAT’S THE DIFFERENCE?
What is a Die Spring?
A die spring is a type of compression spring designed for high forces and to withstand extreme stress in heavy loads in industrial applications. Commonly used in metal stamping and plastic mould tools, as well as a range of demanding industrial applications. Designed to be durable under constant cycling and heavy loads.
The NitroSpring gas spring, however, steps beyond the limitations of traditional die springs. It offers longer service life, greater durability, higher available forces, and a more compact footprint, making it a strong upgrade for applications that demand reliability and performance.
Advantages of NitroSprings over die springs
No preload required
Each NitroSpring is pre-charged, providing force immediately upon contact.
Adjustable forces
A NitroSpring can have a wide range of forces depending on the charge pressure. The pressure adjustment valve feature allows for charging and degassing in the field.
Higher forces from fewer units
NitroSprings deliver greater force output, reducing the number of springs needed and freeing up valuable space while simplifying maintenance.
Longer working travel
With no preload requirement, the entire stroke length is available, offering significantly longer travel than an equivalent die spring.
More compact design
Smaller outside diameters and shorter overall lengths can achieve the same or greater force compared to traditional die springs.
No fatigue-related breakage
Die springs can crack or shed debris as they fatigue. NitroSprings use robust construction to handle demanding environments and support cycle rates up to 150 cycles per minute in standard products.
Multiple fixing methods.
NitroSprings can be fixed to the application with a range of flanges, supports and tapped holes in the cylinder.
Extended service life
Each NitroSpring is designed for a minimum lifetime of 1 million cycles.
Optional corrosion resistance
Available coatings and materials include stainless steels, PVD, powder coating, and other treatments, making them well suited for harsh or contaminated environments.
Superior durability
Debris can lodge between die spring coils and cause premature wear. NitroSprings use a single-cylinder design with advanced sealing to block contaminants.
Constant remote pressure monitoring
Through Bluetooth, wireless, or wired sensors, NitroSprings can be monitored continuously, with automatic alerts if pressure drops.
Comparison case study
5426 Die Spring
EX0320-015 NitroSpring
NitroSpring Advantages
Outside diameter
25mm
24.9mm
Same diameter
Force (F1)
1755N
4573.4N
2.5x more force
Full length
64mm
60mm
-4mm length
Force rate
161N/mm
126N/mm (@3200N)
Force on contact
Deflection
16mm
16mm
Same full deflection
The NitroSpring shows a clear advantage on force and travel.
Upgrading to a NitroSpring
Replacing your die spring
Our NG0, NG1, and NG2 NitroSpring ranges were built to be direct replacements for die springs. Determine what force, diameters, lengths and travel you need to find a suitable NitroSpring for your application. Alternatively, get in touch today or fill out our NitroSpring enquiry form.
Applications where a NitroSpring can be used as a replacement to a die spring
NitroSprings can be used as a replacement or alternative spring type to die springs in most applications. The superior attributes of the NitroSpring offer engineers and designers significant benefits during application design involving spring force.
- Metal stamping tools
- Plastic mould tools
- Industrial machinery
- Food processing machines
- Packaging machinery
- Industrial automation
- Industrial valves
- Mining and Drilling
Frequently Asked Questions
In what market sectors can NitroSprings be used as an alternative to die springs?
- Food packaging machines – they provide a long-life product with 1 million cycles guaranteed. Our NitroSprings can also be manufactured in stainless steel 316/413, or with corrosion resistant coatings. Not to mention, die spring failures can leave debris in the machine, leading to sanitary issues.
- Marine and offshore – stainless steel materials and corrosion resistant coatings are available to ensure Metrol NitroSprings can function in all conditions.
- Mining and drilling applications – the high force, long-life properties make NitroSprings a great alternative to die springs.
- Less NitroSprings ae required as they can have higher forces and are pre-charged.
- Industrial applications – the advantages of a NitroSpring will offer benefits to the user in a wide variety of machines.
- Metal stamping – NitroSprings provide a longer life product.
- Valves – high forces in restricted spaces can be achieved.
- Agricultural machinery – durability, corrosion resistance and long travel offer enhanced performance in Agricultural environments.
Why Die Spring failure causes problems
Failure of a die spring from material fatigue or corrosion can lead to sudden failure through material fracture. Wire debris from a broken spring can damage other parts of an application. NitroSprings are designed to be highly durable with no material fatigue. Any potential failure will not release any harmful material or debris which could affect the application.
Why pre-loading die spring can be a problem
Preloading of a die spring is done to reach a required load at the extended state on an application. Further compression of the spring increases the load as it moves. This can have a number of negative effects including;
- Reducing the working travel of the spring
- Spring design that requires a longer overall length
- Increases material stress and fatigue reducing spring life
- Pre-loading can be dangerous for assembly and maintenance as the springs are under compression
NitroSprings offer a safer more durable solution where the gas spring requires no pre load as its force is generated on contact with the piston rod, at the point where it compresses.
The die spring is not providing the required force
Unfortunately die springs have a fixed spring force by design.
NitroSprings offer the ability to change the force of the spring by altering the charge pressure of the nitrogen. Gas springs therefore have a huge force range as the initial charge pressure can be set between 10 and 200 bar.
I am struggling to fit a suitable die spring into my application
NitroSprings offer a more compact solution compared to die springs, delivering higher forces and longer travel in the same or smaller footprint. Incorporating NitroSprings into your application design gives engineers greater flexibility while optimizing space and improving overall system efficiency.