Ethan Clarke
Soldering inserts into plastic is a useful technique for creating strong connections between plastic and metal parts. This process involves melting the insert into the plastic component using a soldering iron, allowing the plastic to solidify, and resulting in a secure bond. This method is particularly effective for 3D-printed parts, enhancing their functionality and strength. The process requires careful temperature control to avoid overheating and plastic deformation. Additionally, the use of threaded inserts, such as brass inserts, further improves the connection's strength and resistance to pull-out and torque loads.
| Characteristics | Values |
|---|---|
| Soldering iron temperature | A little below the extrusion temperature of the plastic |
| Soldering iron tip | Thick enough so that it doesn't go all the way through the insert |
| Insert depth | 90% of the way in with the soldering iron, then press the rest of the length with a tool |
| Insert type | Heat-set inserts are perfect for thermoplastics in 3D printing |
| Insert material | Metal threaded inserts, typically brass |
| Insert strength | Stronger than plastic threads, rarely overtightened |
| Plastic type | Polycarbonate will melt if you try to solder metal to it |
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What You'll Learn
Soldering iron temperature
The ideal soldering iron temperature depends on the type of plastic being soldered. For instance, the temperature for PLA is around 225 °C, for PETG it is 245 °C, and for ABS, it is 265 °C. Most solder melts around 180 to 190 °C, so the soldering iron must be hotter than this.
If you are using a low-effect iron with a small tip that transfers heat poorly, you may need a temperature as high as 400 °C. On the other hand, if you have a high-effect iron with a large tip that transfers heat efficiently, you won't need as high a temperature. A temperature between 350 °C and 400 °C is usually sufficient.
When soldering plastic, it is important not to overheat the insert. Pull the soldering iron away early, as the threaded inserts store heat and can be pushed the rest of the way in with a tool. You should melt the insert only about 90% of the depth with the soldering iron and press it the rest of the way with a screwdriver or tweezers.
When welding plastic, you should thoroughly clean the plastic with soap and degreaser and sand down the edges so they are not jagged. Push the two pieces of plastic together and hold them as you run the soldering iron tip along the seam. Finally, go over the seam and the surrounding plastic with swift, smooth strokes to create an even weld.
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Insertion technique
Before beginning the insertion, ensure that your plastic has enough outer layers so that the insert is going into mostly-solid plastic. 5 layers at 0.4mm (2mm total) is usually good. Also, make sure that the depth of the hole is greater than the length of the insert, with a hole for air to escape. It is also important to use good-quality inserts with two sets of offset threads.
If you are using a soldering iron, set the temperature to a little below the extrusion temperature of the plastic you are inserting into. You want the plastic to melt, but slowly enough for you to control the direction and depth of the heat-set insert. For example, for PETG plastic, set the soldering iron to 240°C (464°F). Place the heat-set insert right-side up on a thick wooden board, then push the soldering iron into the heat-set insert. Wait a short time for the insert to warm up.
Now, keeping the soldering iron upright and perpendicular to the hole, gently press the insert with the soldering iron as it melts into the plastic. Remove the soldering iron as soon as the insert becomes flush with the plastic's face. Check the insert's height visually, but do not touch it as it will be extremely hot.
Always melt the insert only about 90% of the way in with the soldering iron and press it the rest of the length into the part with a tool such as a screwdriver or tweezers. Hold it in the final position for a few seconds until the plastic has cooled and solidified.
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Insertion depth
When soldering inserts into plastic, it is important to consider the insertion depth to ensure a strong and secure connection. Here are some detailed instructions and tips for achieving the correct insertion depth:
First, ensure that the depth of the hole drilled into the plastic is greater than the length of the insert. This will allow for proper insertion and provide a space for excess molten plastic to escape. It is recommended to have a hole for air to escape through. Additionally, the hole should be drilled into mostly solid plastic. For FDM 3D printed parts, it is recommended to have at least 5 layers at 0.4mm (2mm total) of outer layers.
When melting the insert into the plastic, it is generally recommended to melt the insert only about 90% of the depth with the soldering iron and press it the remaining 10% of the way into the hole with a tool, such as a screwdriver or tweezers. This helps to prevent overheating the insert and plastic, which can lead to decomposition of the plastic and weakening of the connection.
For standard soldering irons, it is suggested to set the temperature to approximately 10-20°C higher than the printing temperature of the plastic. For example, for PLA, set the temperature to around 225°C, for PETG to 245°C, and for ABS to 265°C. If the soldering iron is not adjustable, extra care must be taken to avoid overheating.
When using large inserts, such as M5 or 1/4"-20 camera thread, achieving the required heat for insertion can be challenging. In such cases, it is recommended to use slightly higher temperatures and ensure that the soldering iron tip efficiently transfers heat into the insert. Special soldering tips designed for improved heat transfer are also available.
Finally, once the insert is in place, hold it in position for a few seconds until the plastic has cooled and solidified. This prevents the insert from moving out of position.
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Insertion speed
The insertion speed of the soldering iron is important to ensure a strong connection. The speed should be adjusted to prevent the plastic from melting too quickly and causing the insert to fall off the staker tip. The speed should also be limited to prevent the plastic from springing back during staking and moving the insert.
The insertion speed is dependent on the temperature of the soldering iron and the pressure applied. A higher temperature requires less pressure and vice versa. The ideal temperature and pressure will depend on the specific application and the type of plastic and insert being used.
It is recommended to use a hotend tool to hold and heat the insertion tool, as this allows for more precise placement, temperature control, and insertion speed. This technique also helps to keep the insert perpendicular to the main body of the material.
When using a soldering iron, it is important to ensure that the iron has reached the set temperature before beginning the insertion process. This will help to prevent the plastic from warping due to excessive heat.
During the insertion process, the soldering iron should be applied to the insert for about 10-15 seconds until the insert is about 90% seated into the part. At this point, the iron can be removed, and the part can be flipped onto a flat, heat-resistant surface to be gently pushed down until it is fully seated.
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Insertion strength
Threaded inserts are small metal tubes that are threaded on the inside and knurled on the outside. They are commonly made of brass. When installed into a printed part, they act as the thread for bolts and screws. They can be placed into a printed part by heating them to a temperature that softens the plastic part, allowing the insert to be pushed into an appropriately-sized hole.
The insertion strength of threaded inserts is greater than that of tapped or printed plastic threads, which are prone to overloading and stripping out. Metal threaded inserts provide a stronger and more wear-resistant connection over time. They resist pull-out and torque-out loads with knurled external surface features designed to interface with the bulk material of the larger part.
The strength of the connection is also improved by the increased surface area of the insert in contact with the plastic. This increased surface area distributes the load more evenly, reducing the risk of failure. The exact effectiveness of the insert depends on several factors, including the quality of the insert, the material used, and the printing settings of the plastic part.
To ensure a strong connection, it is important to follow the correct installation procedure. The insert should be heated to a temperature that softens the plastic without overheating and deforming it. The insert is then pushed into the hole, and the cooling plastic hardens around it, creating a solid connection. The insert should be allowed to cool for a few minutes before use so that the plastic has time to set.
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Frequently asked questions
The best way to solder an insert into plastic is to use a soldering iron to melt the insert into the plastic. The soldering iron should be set to a temperature that is a little below the extrusion temperature of the plastic. This will ensure that the plastic melts slowly enough for you to control the direction and depth of the insert.
You should use a standard or adjustable soldering iron. If you are using an adjustable soldering iron, set the temperature to approximately 10-20°C higher than the printing temperature of the plastic.
Metal threaded inserts are the strongest option for plastic parts. Brass heat-set inserts are commonly used for 3D printed parts.
It is important to avoid overheating the insert, as this can cause the plastic to decompose. It is also important to ensure that the hole in the plastic is large enough to accommodate the insert. Additionally, be sure to use a thick enough soldering iron tip to prevent it from going all the way through the insert.
