Official Answer
Answer
Solid height is the theoretical height when the spring is compressed until all waves are in contact. If a wave spring is compressed to its solid height, the bending stresses $S = \frac{3 \pi P D_m}{4 b t^2 N^2}$ often exceed the yield strength of the material. This causes permanent deformation, where the spring will not return to its original free height. In troubleshooting, if a spring shows 'flat spots' on the crests or a reduced free height, it is likely the assembly allowed the spring to be over-compressed. Designers should always include a positive stop in the housing to prevent the spring from reaching its solid height during over-load conditions.
