Sofia Martinez
Threaded inserts are a common type of hardware used to create strong machine threads in plastic components. They are used in materials that are too thin to have threads machined into them or to repair worn-out fastenings in corroded materials. There are various methods to install threaded inserts in plastic, such as using a soldering iron, heat staking, ultrasonic, moulded-in, or cold-pressed-in processes. The type of insert and installation process depends on the application and the strength requirements. For example, thermoset plastics require inserts to be placed before they cool, while thermoplastics can be melted and reformed multiple times. When installing threaded inserts, it is important to design the hole correctly and use good quality inserts with offset threads.
How to Install Threaded Inserts in Plastic
| Characteristics | Values |
|---|---|
| Materials | Plastic, Metal, Brass, Stainless Steel |
| Types | Ultrasonic (or Heat-Set), Press Inserts |
| Use Cases | 3D printing, thermoset plastics, post-fabrication molds, industrial applications, electronics, automotive, aerospace, defense, medical, industrial, recreational equipment, handheld devices |
| Installation Process | Heat staking, ultrasonic, molded-in, cold pressed-in |
| Installation Considerations | Hole design, iron temperature, iron cleanliness, iron tip thickness, outer layers of plastic, depth of insert, air hole |
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What You'll Learn
Using a soldering iron
First, ensure you have the correct tools and materials. You will need a soldering iron, preferably with adjustable temperature settings. If your soldering iron has tips, consider using a thicker tip to avoid it going all the way through the insert. You can also purchase special heat-set insert tips designed specifically for this task. Additionally, you will need the threaded inserts themselves, and the plastic part you wish to modify.
Before beginning the installation, it is important to design the hole correctly. The hole should be deep enough to accommodate the length of the insert, and it is recommended to have a hole for air to escape through. The insert requires a tapered cavity of a specific size, so refer to the recommended dimensions provided by the insert vendor.
Once the hole is prepared, set the soldering iron to the appropriate temperature. The ideal temperature will depend on the type of plastic being used. It is recommended to set the iron to the melting point of the plastic, without exceeding the maximum temperature specified for that material. For 3D-printed parts, the temperature can be approximately 10-20°C higher than the printing temperature. For example, around 225°C for PLA, 245°C for PETG, and 265°C for ABS.
With the soldering iron heated to the correct temperature, apply it to the insert. The insert will start to descend into the plastic once it exceeds the plastic's melt temperature. Use the side of the soldering iron tip, rather than the point, to press the insert straight down into the hole, ensuring it remains flush with the top of the part. Be careful not to overheat the insert, as this can lead to plastic decomposition.
After embedding the insert, remove the soldering iron and allow the plastic to cool for a few minutes. This will give the plastic time to set and strengthen the connection. You can use this time to adjust any inserts that may not be seated correctly.
By following these steps, you can successfully install threaded inserts into plastic parts using a soldering iron. This method ensures a strong and durable connection, enhancing the functionality and appearance of your plastic components.
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Insert type and size
Threaded inserts for plastics come in various types and sizes. The type and size of insert you need will depend on your specific application and requirements.
Insert Types
- Ultrasonic (or Heat-Set) Inserts: These inserts are designed for use in thermoplastics. They are placed using an ultrasonic horn, which vibrates at a high frequency, generating heat through friction. This heat melts the surrounding plastic, allowing the insert to be placed and creating a firm seal as it cools. 3D printing applications often use this type of insert.
- Press Inserts: These inserts can be used in both thermoset plastics and thermoplastics. They have a simple installation process and do not require heat. Press inserts are ideal for thermoset plastics, as they can be placed before the material cools or without the need for heat.
- Metal Threaded Inserts: Metal inserts provide strong and reusable joints for plastic parts. They are a good option if the plastic parts need to be taken apart and reassembled multiple times. Metal inserts offer high pullout force and torque-out force resistance.
- Brass Inserts: Brass threaded inserts are commonly used for 3D printing projects and are set after the part has been fabricated. Brass is a soft metal, so it is easy to work with and can be installed after fabrication.
Insert Sizes
- Standard threaded inserts for plastics typically range from 1/8" to 9/16" in diameter and 1/8" to 5/8" in length. Thread sizes can vary from #0-80 to 3/8-16 (M2 to M10).
- MicroPEM inserts are available for physically smaller applications, with diameters as small as 1 mm and lengths of 1.75 mm. These can accommodate an M1 fastener.
It is important to consider the specific requirements of your application, such as strength, reusability, and the type of plastic being used, when selecting the appropriate insert type and size. Testing different options is recommended to determine the exact size and type needed before production.
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Hole design
Firstly, the hole should be designed with the appropriate diameter and length to accommodate the selected threaded insert. Standard threaded inserts for plastics typically range from 1/8" to 9/16" in diameter and 1/8" to 5/8" in length. However, for smaller applications, microPEM inserts are available, with diameters as small as 1 mm and lengths of 1.75 mm. Ensure that the depth of the hole is greater than the length of the insert to allow for proper insertion.
Additionally, when designing the hole, consider the number of outer layers of plastic that will surround the insert. It is recommended to have sufficient outer layers to provide a solid base for the insert. For example, in 3D printing, having 5 layers at 0.4 mm each (a total of 2 mm) can provide a good foundation for the insert. Also, ensure that the hole is designed with a means of escape for air to prevent air pockets from forming during the insertion process.
The knurling pattern on the insert also plays a crucial role in hole design. Knurling is a metalworking process that creates a pattern on the surface of the insert, enhancing its grip with the plastic. Straight knurls, which are parallel to the length of the insert, offer greater resistance to torque, while grooves between knurl bands increase pull-out resistance. Therefore, depending on the specific requirements, the hole design should take into account the knurling pattern to maximize the insert's grip and stability.
Furthermore, when designing the hole, consider the type of plastic being used. Thermoplastics, such as those used in 3D printing, can be melted and reformed multiple times without affecting their durability. In contrast, thermoset plastics undergo chemical reactions during heating and cooling, so the inserts must be placed before the plastic cools, or non-thermal installation methods must be employed. Thus, the hole design should accommodate the specific characteristics and requirements of the chosen plastic type.
Lastly, the hole design should also consider the insertion process. There are four main categories of insertion processes: heat staking, ultrasonic, molded-in, and cold pressed-in. Each process has unique benefits and requirements. For example, the ultrasonic process uses an ultrasonic horn to generate heat and melt the surrounding plastic, requiring a hole design that facilitates the application of ultrasonic energy. Therefore, the hole design should be optimized based on the selected insertion process to ensure a secure and effective installation.
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Insertion process
The insertion process for threaded inserts in plastic depends on the type of plastic and insert being used. Here is a step-by-step guide for installing threaded inserts in plastic:
- Design the Hole: The first step is to design the hole correctly for the threaded insert. Consider the size and type of insert required for your specific application. Standard threaded inserts for plastics typically range from about 1/8" to 9/16" in diameter and 1/8" to 5/8" in length. MicroPEM inserts are available for smaller applications, with diameters as small as 1 mm. Additionally, ensure that your 3D printing design includes pilot holes in all the locations you wish to place the inserts.
- Prepare the Insert: Choose the right insert for your application. Metal threaded inserts, such as brass or stainless steel, are ideal for creating strong and reusable joints in plastic parts. If you are using thermoplastics, consider using ultrasonic or heat-set inserts, which can be placed using an ultrasonic horn that melts the surrounding plastic and creates a firm seal as it cools. For thermoset plastics, use non-thermal installation processes like press inserts or ensure the inserts are placed before the plastic cools.
- Prepare the Plastic Component: When working with 3D printing, ensure that you have sufficient outer layers so that the insert is going into mostly-solid plastic. A depth greater than the length of the insert is recommended, preferably with a hole for air to escape.
- Apply Heat: If using a heat-staking or ultrasonic process, set your heat source (such as a soldering iron) to the melting point of the plastic. Avoid exceeding the maximum temperature to prevent deforming the plastic. Ensure your equipment is clean and properly prepared to avoid any issues during insertion.
- Insert Placement: Carefully insert the threaded insert into the hole. If using a soldering iron, ensure that the insert does not stick to the iron, as this can cause issues when removing it. Apply pressure to the top of the insert until it is placed correctly in the desired location.
- Cooling: If you used a heat-staking or ultrasonic process, allow the plastic to cool and harden. As it cools, the plastic will create a strong bond with the insert, ensuring a firm seal.
By following these steps and considering the specific requirements of your application, you can successfully install threaded inserts in plastic, creating strong and secure joints.
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Thermoplastics vs. thermoset plastics
Threaded inserts are a common type of hardware used to create strong machine threads in plastic components. They are used in materials that are too thin to have threads machined into them or to repair worn-out fastenings in corroded materials. Brass threaded inserts are typically used for 3D printing projects and are set after the part has been fabricated.
When deciding on the type of threaded insert to use, it is important to consider the type of plastic being used. Thermoplastics and thermosetting plastics are two distinct types of polymers that behave differently under heat. Thermoplastics can be heated, cooled, and reshaped repeatedly without altering their chemical structure. They do not form any chemical bond when curing, making them remouldable and recyclable. On the other hand, thermosetting plastics undergo a chemical change when heated, forming irreversible bonds that permanently set their shape. Thermosets are stronger and more heat-resistant than thermoplastics due to their three-dimensional bonding. They also have excellent resistance to corrosion, heat, and mechanical creep. However, thermosets will often degrade before melting when exposed to excess heat.
When installing threaded inserts in thermoplastics, the inserts are placed using an ultrasonic horn that vibrates at a high frequency, generating heat through friction. The heat melts the plastic surrounding the insert, and as it cools, it hardens and creates a strong bond with the insert. This process is suitable for 3D printing applications. For thermoset plastics, the inserts must be placed before the plastic cools or non-thermal installation processes must be used, such as press inserts.
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Frequently asked questions
Threaded inserts for plastics are hardware used to create strong machine threads in plastic components. They are used in materials that are too thin to have threads machined into them or to repair worn-out fastenings in corroded materials.
There are four main methods of installing threaded inserts in plastics: heat staking, ultrasonic, moulded-in, or cold pressed-in. The best method depends on the part requirements. For example, if the plastic part needs to be taken apart and reassembled, metal threaded inserts are the best option.
When designing the model for 3D printing applications, the design should include pilot holes in all the locations you wish to have a plastic insert. It's also important to design the hole correctly for the threaded insert you are using. Make sure to use a good quality insert with two sets of offset threads.
