New measuring instruments for precision springs quality

Mollificio Romagnoli has been manufacturing precision springs and elastic components for decades, serving industries such as automation, electromechanics, medical, and hydraulics. Product quality also stems from the ability to measure, analyze, and predict material behavior. For this reason, the company has invested in a new high-definition digital microscopy system, aimed at further improving the reliability of inspections on coiled wire and surface treatments.

Today’s article explores how this new instrument is transforming quality control and maintenance operations, highlighting its practical applications in the production of springs and small metal parts.

More accurate analysis of surface treatments

Inspecting the wire surface condition is one of the most critical steps in industrial spring manufacturing. Scratches, micro-ovalizations, drawing imperfections, or machining residues can compromise the service life of components in dynamic applications.

Thanks to the E20 and E100 lenses (20–100× with a 30 mm depth of field and 100–500× with a 24 mm depth of field, respectively), Mollificio Romagnoli can now capture images with a much higher level of detail than traditional optical systems. The greater depth of field and the ability to switch from low to high magnification without changing lenses make it possible to detect previously invisible defects.

Counting coils on microscopic springs

Among the most significant applications is the ability to count coils on extremely small springs — for example, components less than 5 mm long with 0.2 mm wire. The new instrument allows users to move seamlessly from a panoramic magnification to a detailed close-up without losing focus, providing clear measurements even on complex geometries and very small diameters. This improves repeatability in inspections and reduces the risk of manual errors.

Inspection of spring ends, grinding quality, and micro-burrs

Another enhanced area concerns the analysis of spring ends:

• absence of burrs
• grinding quality
• flatness and uniformity of the support surface

The ability to detect small irregularities using multi-angle lighting and glare-free imaging enables a more reliable inspection than standard optical solutions. This makes it possible to anticipate potential assembly issues and improve the spring’s performance in operation.

Inspection of coiled wire and predictive tool maintenance

Coiled wire analysis plays a central role in the production process. High magnification and large depth of field help identify micro-damage, wear marks, minor flattening, or defects generated during the coiling phase.

The same approach is now applied to tooling: monitoring their condition at regular intervals allows early wear detection and helps prevent unplanned downtime. Digital microscopy therefore also becomes a predictive maintenance tool.

If you would like to learn more about Mollificio Romagnoli’s customized solutions for springs and elastic components, contact the company for a dedicated consultation.