Sofia Martinez
Plastic inserts, also known as threaded inserts, are materials or components embedded or integrated into plastics to enhance their strength and durability. They are used to create strong, usable threads in plastic parts, providing additional strength, improving functionality, and enabling assembly with other parts. Various types of plastic inserts are available, such as press-fit, tapping, heat-set, helical, and mold-in inserts, each serving specific purposes and applications. The choice of insert material, such as brass, stainless steel, or aluminum, depends on the application and the type of plastic being used. Plastic inserts can be installed using different methods, including ultrasonic, thermal/heat, or press-in techniques, ensuring optimal performance and durability. Additionally, plastic inserts can be customized to meet specific requirements, offering versatility and adaptability in manufacturing processes.
| Characteristics | Values |
|---|---|
| Name | Threaded inserts for plastics, Rivet nuts, Bulge inserts |
| Purpose | To provide additional strength, improve functionality, enable assembly with other parts, and preserve bolted joint integrity |
| Materials | Brass, Steel, Stainless steel, Aluminium, Thermoplastics, Thermosets |
| Types | Heat-set, Helical, Press-fit, Tapping, Mold-in, Dowel pin, Chevron, Tapered, Expansion, Press-in, Symmetrical, Molly Jack, Riv-Float, Round-body, Stud-style, Spin-spin, Spin-pull |
| Use Cases | Medical devices, 3D printed parts, Injection moulding, CNC machined plastics, Leveling screws on heavy equipment, Thin/brittle/soft materials, Off-center installations, Sheet metal, Heavy-duty applications |
| Benefits | Enhanced strength and durability, Secure attachment points, Wear resistance, Versatility, Consistency, Cost-effectiveness, Reusable threads, Permanent creep resistance |
| Considerations | Insert material, Plastic material, Installation process, Pull-out force, Torque-out force, Knurling pattern, Hole type, Panel hardness, Load-bearing capacity |
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What You'll Learn
- Metal threaded inserts are ideal for plastic parts that need strong joints and reusable threads
- Heat-set inserts are used in medical devices and equipment, creating sterile attachment points
- Ultrasonic and heat-staking insertion processes are only compatible with thermoplastics
- Thermosets require specialised inserts like moulded-in, press-in, or self-tapping inserts
- Rivet nut inserts are versatile and can be used to create a lasting bond in any material
Metal threaded inserts are ideal for plastic parts that need strong joints and reusable threads
Metal threaded inserts are ideal for creating strong joints and reusable threads in plastic parts. They are commonly used in applications that require strong and durable threads inside plastic materials. Metal threaded inserts are often used when plastic parts need to be taken apart and reassembled multiple times, as they provide a sturdy and reusable fastening option.
There are various types of metal threaded inserts available, each with unique advantages. For instance, heat-set inserts are used in medical devices, creating sterile attachment points in plastic housings and enclosures. Helical inserts, also called coil inserts or thread inserts, are used to reinforce or repair damaged threaded holes in plastic components. Pressed-in inserts, also known as expansion inserts, feature slots that allow them to flex during insertion and create a strong bond with the hole's wall.
When selecting metal threaded inserts for plastics, it's important to consider the type of plastic and the specific application. Thermoplastics, such as PMMA, PC, and ABS, work well with heat-staking and ultrasonic insertion methods. Thermosets, on the other hand, require molding or cold pressing the insert. Brass is a commonly used material for threaded inserts, but stainless steel and aluminum are gaining popularity due to their strength, corrosion resistance, and lightweight properties.
Metal threaded inserts for plastics provide several benefits. They enhance the strength and durability of plastic parts by improving pull-out and torque resistance. They also offer versatility, consistency, and cost-effectiveness. Additionally, metal threaded inserts facilitate easy assembly and disassembly, making them ideal for applications where parts need to be frequently accessed for maintenance or repair.
Metal threaded inserts are widely used across various industries, including electronics, automotive, aerospace, defense, and recreational equipment. They are valuable in manufacturing and repair processes, providing a secure and reusable method for attaching and detaching parts.
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Heat-set inserts are used in medical devices and equipment, creating sterile attachment points
Heat-set inserts are a type of threaded insert used in plastics to create sterile attachment points for medical devices and equipment. Threaded inserts are materials or components embedded or integrated into plastics to enhance their strength and durability, improve functionality, and enable assembly with other parts.
Heat-set inserts are ideal for medical devices as they create sterile and hygienic attachment points in plastic housings, instrument panels, and enclosures. They meet strict regulatory requirements for medical device assembly and sterilization processes, ensuring product safety and reliability. The inserts are heated and pressed into pre-molded holes in plastic parts. As the insert cools, it forms a strong bond with the surrounding plastic, creating a secure attachment point for fasteners.
The process of installing heat-set inserts involves placing the insert above its cavity and ensuring it is straight and centered. The tip of an iron is then lined up with the center of the insert, and slight pressure is applied while the insert heats up. Once the insert reaches the plastic's melt temperature, it begins to descend into the part. It is important to guide the insert straight into the hole to avoid inserting it at an angle. After embedding all the inserts, they are allowed to cool for a few minutes to let the plastic set.
Heat-set inserts are commonly used with thermoplastics, which can be reshaped multiple times and work well with heat and ultrasonic inserts. During installation, the thermoplastic melts and reflows around the insert, creating a secure bond and enhancing the pull-out and torque-out rating of the resulting thread. Metal threaded inserts, typically made of brass, are often used for plastic parts to provide strong joints and reusable threads.
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Ultrasonic and heat-staking insertion processes are only compatible with thermoplastics
Threaded inserts are materials or components embedded or integrated into plastics to enhance their strength and durability. They serve various purposes, such as providing additional strength, improving functionality, or enabling assembly with other parts. Ultrasonic and heat-staking insertion processes are commonly used for threaded inserts in injection-molded parts. These processes involve melting the plastic around the insert to create a strong bond.
Ultrasonic insertion uses high-frequency ultrasonic acoustic vibrations to soften the plastic and press fit the insert into the part geometry, creating a solid-state weld. It is known for its speed, reliability, and versatility, as it works with most thermoplastics. The process uses standard 20kHz welders, which are widely available. However, ultrasonic insertion can be abrasive and generate metal dust, which may be undesirable in certain applications. It also creates a larger process-affected zone that can result in chipping of the material.
Heat staking, on the other hand, involves heating the threaded insert and press-fitting it into the part. This process is commonly used in manufacturing appliances, automotive parts, and equipment in the telecom industry. It relies on precise control and application of temperature and pressure to reform the plastic. Heat staking is a gentler method than ultrasonic insertion, reducing the risk of damaging the insert and promoting better plastic flow during installation, leading to a more secure fit.
Both ultrasonic and heat-staking insertion processes are compatible with thermoplastics. Thermoplastics are a versatile class of polymers that are rigid and solid at normal temperatures but soften and melt when exposed to higher temperatures. This property allows thermoplastics to work well with heat staking and ultrasonic insertion processes, as the plastic can be re-melted to create a strong bond with the insert.
In contrast, thermosets, such as epoxy and vulcanized rubber, require specialized inserts like molded-in or press-in inserts. Thermosets are permanently rigid after molding and do not soften or melt when exposed to higher temperatures. Therefore, ultrasonic and heat-staking insertion processes, which rely on re-melting the plastic, are not compatible with thermosets.
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Thermosets require specialised inserts like moulded-in, press-in, or self-tapping inserts
Thermosets, such as epoxy and vulcanised rubber, become permanently rigid after moulding and require specialised inserts. Unlike thermoplastics, which can be reshaped multiple times and work well with heat and ultrasonic inserts, thermosets necessitate the use of moulded-in, press-in, or self-tapping inserts.
Moulded-in inserts are the most stable option for thermosets. They are placed into the mould before the moulding operation, allowing the plastic polymer to encapsulate the insert and set it in place. This method does not require a secondary operation to drive in or press-fit the inserts, but the mould must be designed correctly to ensure the plastic does not enter the internal threads. Moulded-in inserts provide the best overall bond and eliminate the need for subsequent insertion processes.
Press-in inserts, also known as pressed-in or cold-pressed inserts, are another option for thermosets. This method involves pressing the insert into the thermoset plastic mould after the moulding process. Press-in inserts are easy to install, economical, and do not require special equipment. However, they have a weaker bond and lower torque rating than other methods, making them less suitable for applications where the insert may be at risk of damage or being pulled out.
Self-tapping inserts, also known as driven inserts, are installed into preformed holes in the thermoset material. The insert's external threads cut their own threads into the material as it is screwed in. Self-tapping inserts provide greater stability than press-in inserts, but they require additional equipment, such as a drill or driver, and may have longer installation durations. They are generally recommended for softer thermosets to avoid cracking.
When selecting inserts for thermosets, it is important to consider the application, environment, and geometries of the moulded parts. The elasticity of the resin material is also critical for successful insertion. Additionally, the material of the insert itself is a key consideration, with brass, stainless steel, and aluminium being common choices, each offering different advantages in terms of cost, weight, strength, and corrosion resistance.
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Rivet nut inserts are versatile and can be used to create a lasting bond in any material
Rivet nut inserts are a versatile fastening solution, used across a wide range of industries and applications. They are used to create a strong, lasting bond in any material, from plastics and metals to wood and ceramics. They are especially useful when working with thin or soft materials, such as sheet metal, aluminium, and consumer electronics, as they can provide reliable threads and a secure connection.
Rivet nut inserts are also commonly used in aerospace, transportation, clean energy, medical applications, and manufacturing settings. They are ideal for repairing stripped threads and creating a fast, long-lasting bond. They are also useful for connecting disparate materials, such as plastic and metal, and for applications that require repeated assembly and disassembly.
The versatility of rivet nut inserts extends to the variety of configurations and types available. The original rivet nut, developed in the 1930s for airplane manufacturing, is the thick wall insert, or nutsert, which usually has a round or hexagonal body. Other types include stud-style inserts, which are used when a nut is preferred over a bolt, and Molly Jack inserts, which are made from steel, brass, or coated steel, and are ideal for thin, brittle, or soft materials.
When choosing the proper rivet nut insert, it is important to match the insert to the material. For softer materials, such as wood or plastic, a softer material like brass or aluminium should be used for the insert. Harder materials, such as steel or stainless steel, may cut through softer materials. Additionally, the type of insertion process will depend on the material. Thermoplastics, for example, work well with heat and ultrasonic inserts, while thermosets require specialised inserts like moulded-in or press-in inserts.
Rivet nut inserts are a reliable and versatile fastening solution, offering strong and lasting bonds in a wide range of applications and materials. With their ease of installation and variety of configurations, they are a popular choice for creating secure connections.
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Frequently asked questions
Plastic bulge inserts are called rivet nuts. They are one-piece, internally threaded and counterbored tubular rivets that can be anchored entirely from one side. They are used to create a bulge on the back side of a panel as a screw is tightened in its threads.
Rivet nuts are used to create a lasting bond in any material. They are popular with thin materials, such as consumer electronics, or soft materials used to make furniture, such as pine. They are also used for leveling screws on heavy equipment.
There are two basic types of rivet nut installations. The first design creates a bulge to secure the rivet nut on the back side, and the bolt is tightened in the insert. The second design draws in the sleeve when the bolt is tightened to press against the sides of the pre-drilled hole, thus creating a strong bond.
