Answer
The solid height $H_s$ of a Crest-to-Crest wave spring is not merely the sum of material thicknesses. It is calculated as $H_s = (N \times t) + (N-1) \times t_{contact}$, where $N$ is the number of turns and $t$ is the material thickness. In practice, due to manufacturing tolerances in wave formation and the 'set' taken during the first compression, the actual solid height may be slightly higher than the theoretical sum. Engineers must ensure that the operating height $H_{op}$ is always greater than $H_s$ by a safety margin of at least $10\%$ of the wave height to prevent the spring from acting as a solid shim, which would transfer the full load through the material in compression rather than bending, potentially exceeding the material's compressive yield strength.
