Forward-thinking Solutions

For over 40 years, PJ Wallbank Springs has partnered with our customers to develop new products. While preparing a complex new product, our customers’ engineers often oversee development across various products, making it difficult to have deep expertise in any specific components. With that said, it’s these details often lead to the best product design, whether from best practices developed over the years, designing for manufacturability, or optimizing the design for both function and cost, which are often competing factors.

Many industrial customers prefer to work with a trusted advisor who has already designed and manufactured hundreds of similar applications. We are structured to achieve this, and we take it as our responsibility to ensure that each customer has an application design that is cost-effective, easy to manufacture, and meets their specific requirements.  

Continuous Improvement for Consistent Quality

When PJ Wallbank Springs opened in 1982, we manufactured exclusively to customer-designed prints. Through this, we realized products often weren’t optimized for cost and manufacturability was low, usually because our customer lacked enough time or the necessary expertise.

From designing and manufacturing over 400 spring assembly designs, we’ve developed proprietary spring assembly software that captures best practices and lessons learned over our 40 years and filters all new designs through this system.  

One significant advantage of this software is that products are designed with manufacturability in mind right from the initial concept. This eliminates the risk of repeating mistakes we’ve already learned from or throwing designs over to manufacturing to “figure out”, which is a common challenge in nearly any manufacturing organization.

3 ways we work with our customers:
  1. Clean sheet (cross-section of available space and customer’s requirements)
  2. Optimize customer’s existing print
  3. Build to print

While any of the above approaches can be supported, clean sheet approaches generally result in the lowest product costs and best manufacturability.

Common reasons for higher-cost designs are excessive use of materials, type of materials used, and special processing or additional process steps required. To avoid these situations, we work tirelessly to ensure our customers have optimized designs through FEA, bench testing, prototyping, supplier collaboration, our proprietary design software, and our best practices.

Contact our team to get started 
on a custom solution