Wire diameter directly affects spring rate and load capacity — a thicker wire produces a stiffer spring. For light return or damping duties (e.g., small levers, drawer mechanisms), wire diameters of 0.3 mm – 0.8 mm are typically sufficient. For moderate clamping or valve return applications, 1 mm – 2 mm wire is a common starting point. For heavy mechanical loads or high-cycle industrial use, 2.5 mm – 5 mm wire diameters are more appropriate. If you know the required load at a specific deflection, use the spring rate formula (Rate = (G × d⁴) / (8 × D³ × n)) or contact us for guidance.