From tradition to
digital connectivity

>Digitalization of spring production, an industry that is traditionally anchored in mechanical engineering<

Federnfabrik Schmid AG has set itself this ambitious goal. With the support of Innosuisse, the Zurich-based medium-sized company has been 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 allows it to integrate components that can assess the condition of the springs in real time, representing a small revolution in the field.

Springs are omnipresent in our everyday lives and are used in a 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. They act as actuators that provide safety and exert force in objects such as watches, wind turbines and satellites. The SME he heads, founded in 1912, specializes in the supply of high-precision industrial springs. Today, it employs around sixty people and exports around 80% of its production. The springs of various sizes are made from different metals and alloys.

Time-limited elasticity

Although the spring is an essential component and many objects and applications rely on it to function properly, it has a weak point. Its 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 leading to high repair costs," explains Dr. Cord Teller, Head of Technical Sales.

From mechanical springs to intelligent springs

Failures, replacement costs etc. therefore have many consequences for manufacturers. “We have recognized that the failure of springs 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 the spring was not integrated into the digital world of machines. So we came up with the idea of developing a networked spring," explains Albert Enste.

The idea was born, but there was a lack of technical expertise to develop such a project in an SME. “We needed very precise knowledge of 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 prototype of I-Spring was developed.

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

The need for innovation

Today, the prototype of the intelligent 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 in transforming the company's business model. "This innovation represents a revolution in the field of springs. It will completely change our business model and is already changing the way our customers and employees perceive us.

For Federnfabrik Schmid AG, this step towards digitalization and connectivity is also an opportunity to secure its long-term future. "As a traditional SME, we see innovation as a real opportunity. Not only does it allow us to diversify our activities and explore new horizons, but it also opens the doors to new markets. The impact on the company is also important. 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!