What are the risks associated with 'nesting' multiple wave springs and how should they be addressed?

Nesting involves stacking multiple single-turn wave springs in parallel to increase the load capacity (load scales by the number of springs). The primary risk is friction between the layers, which introduces hysteresis in the load-deflection curve and generates heat during cyclic operation. Misalignment of the wave peaks between nested layers can also cause localized stress spikes and non-uniform loading. To address this, nested springs should ideally be manufactured as a single continuous 'interlaced' or multi-turn nested spring where the coils are produced together, ensuring perfect synchronization of the waves.