Alexei Volkov
Plastic inserts are used in a variety of applications, from 3D printing to medical devices. They are often used to create strong joints and machine threads in plastic components, providing additional strength, improving functionality, and enabling assembly with other parts. There are several types of plastic inserts available, including ultrasonic or heat-set inserts, press inserts, and self-tapping inserts. The type of insert used depends on the specific application and the materials involved. For example, thermoplastics can be melted and reformed multiple times, whereas thermoset plastics cannot be melted again, requiring inserts to be placed before cooling. Plastic inserts can also be used with softwoods and other materials to enhance strength and durability.
| Characteristics | Values |
|---|---|
| Names | Rawl plugs, wall plugs, plugs, drywall anchors, inserts, threaded inserts, compression limiters, SI threaded inserts |
| Materials | Thermoplastics, thermoset plastics, softwoods, plywood, chipboard, metal, stainless steel, brass |
| Use cases | To strengthen plastic, create strong machine threads in plastic components, improve functionality, enable assembly with other parts, create sterile and hygienic attachment points, repair worn-out fastenings, create strong joints, provide additional strength |
| Types | Helical, opposed knurls, rounded knurls, herringbone knurls, self-tapping, expansion inserts, heat staking, ultrasonic, molded-in, cold pressed-in, heat-set, press inserts |
| Installation methods | Heat/ultrasonic, press-in, molded-in, drilling, 3D printing, CNC machining, injection molding |
| Strength factors | Pullout force, torque-out force, resistance to twisting |
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What You'll Learn
Plastic inserts for 3D printing
When it comes to 3D printing, plastic inserts are commonly referred to as threaded inserts. These inserts are used to add threads to 3D-printed parts made from thermoplastics. Thermoplastics are ideal for 3D printing because they can be moulded and remoulded repeatedly, allowing for design adjustments and corrections.
There are several types of threaded inserts available, each with its own advantages and considerations. Heat-set inserts, for example, are perfect for thermoplastics because the installation process involves melting the plastic, which then reflows and solidifies around the insert, creating a strong bond. This method requires specific tools and a tapered cavity for the insert to descend into as it melts the plastic.
Another type of insert is the cold-pressed insert, also known as an expansion insert. These inserts are easy to install, often requiring only finger pressure, and are highly economical. However, they may not offer the same performance as heat-set inserts.
Ultrasonic inserts are another option, using vibration frequency instead of heat to melt the plastic and create a bond. This method is comparable in speed to heat staking but requires precise control and can be loud and challenging to automate.
The choice between these insertion processes depends on various factors, including design requirements, cost, and performance expectations. Additionally, the strength of the bond between the insert and the plastic part is an important consideration, with factors like pull-out force and torque-out force playing a crucial role in determining the overall strength.
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Plastic inserts for thermoplastics
Plastic inserts are used to fortify the connection points within plastic assemblies. They are designed to be used with specific materials, such as thermoplastics and thermoset plastics, as well as soft woods like plywood and chipboard. Thermoplastics, for instance, are materials that remain solid at usable temperatures but become soft at elevated temperatures. Common thermoplastics include PVC, nylon, polypropylene, and polyethylene.
There are various types of plastic inserts available, each with unique benefits and features catering to different design requirements. The four main categories of insertion processes are heat staking, ultrasonic, molded-in, and cold pressed-in. Heat staking is a commonly applied process for thermoplastic materials as it is easy to control, low cost, and lends itself well to automation. Ultrasonic inserts are also designed for use in thermoplastics, creating a vibration frequency that melts the plastic. Cold pressed-in inserts are highly economical as they are easy to install and do not require special auxiliary equipment.
Metal threaded inserts are ideal for plastic parts that need to be strong and reusable. They are often used in applications across different industries, such as electronics, automotive, and aerospace. For instance, in electronics, they can securely fasten components within plastic enclosures, ensuring the integrity of sensitive devices. In the automotive and aerospace industries, they play a crucial role in assembling plastic components in vehicles and aircraft.
The key strength factors of plastic inserts are the resistance to the insert pulling out of the part (pullout force) and the resistance to the insert twisting when the fastener is torqued (torque-out force). The length and diameter of the insert impact these resistance capabilities. Knurling, a process within metalworking where a pattern is cut or rolled onto the outside of the product, is critical to achieving the desired pull-out and torque resistance.
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Plastic inserts for thermoset plastics
Plastic inserts are used to join plastic components and are available for both thermoset plastics and thermoplastics. Thermoset plastics undergo an irreversible chemical change during the moulding process and can be shaped only once. Thermoplastics, on the other hand, can be moulded and remoulded repeatedly without causing any chemical changes.
There are various types of inserts available for use with plastics, including those with helical and opposed knurls, self-tapping inserts, and metal threaded inserts. The type of insert used depends on the specific requirements of the application. For instance, metal threaded inserts are ideal for plastic parts that need to be taken apart and reassembled multiple times.
Key strength factors to consider when selecting an insert include resistance to the insert pulling out of the part (pullout force) and resistance to the insert twisting (torque-out force). The longer the insert, the greater the pull-out resistance, and the greater the diameter, the more torque capacity it holds. Knurling is a critical process in threaded inserts, as it improves pull-out and torque resistance.
There are four main categories of insertion processes: heat staking, ultrasonic, moulded-in, and cold pressed-in. Heat staking is commonly applied to thermoplastics as it is easy to control and lends itself well to automation. Ultrasonic insertion can be used for both thermoset plastics and thermoplastics. It creates a vibration frequency that melts the plastic, but it can be loud and harder to automate. Press inserts, such as the E-Z Press Inserts and E-Z Fin (Finserts), are also suitable for both types of plastics and offer benefits like minimal splitting and easy press-in installation.
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Metal threaded plastic inserts
There are various types of metal threaded plastic inserts available, including chevron, tapered, expansion, press-in, mold-in, and symmetrical threaded inserts. Flanged options are also available. Metal threaded plastic inserts can be installed using heat staking, ultrasonic, moulded-in, or cold press-in methods. Heat staking is a commonly applied process for thermoplastic materials as it is easy to control, relatively low cost, and lends itself well to automation. Ultrasonic installation uses vibration frequencies to melt the plastic, and while it is comparable in speed to heat staking, it requires precise control and can create a larger process-affected zone that may result in chipping of the material. Moulded-in installation is ideal for creating strong threads in thermoplastic parts, while cold press-in installation is a highly economical alternative as it is easy to install and does not require special auxiliary equipment.
When selecting metal threaded plastic inserts, it is important to consider factors such as insert type, application, cost, and other components to ensure optimal performance and durability. Proper installation practices are crucial, and companies like E-Z LOK and MW Components offer installation guides to assist customers in seamlessly integrating their products into plastic assemblies.
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Plastic inserts for medical devices
Plastic inserts are used in medical devices to improve performance and simplify the assembly process. Injection-moulded plastics can be used as inserts in products such as overmoulded diaphragms and gaskets, where increased rigidity is needed to ease product assembly or to obtain improved permeation resistance. Insert moulding can also eliminate the need for assembly, allow for areas of colour contrast, and provide greater design aesthetic to the finished medical device.
Injection moulding is a commonly applied process for thermoplastic materials, where softened resin flows into the knurl pattern and hardens to form a firm bond with the insert. The knurling pattern is critical to the pull-out and torque resistance of the plastic insert. The longer the insert, the greater the pull-out resistance, and the greater the diameter, the more torque capacity it holds.
There are four categories of insertion processes: heat staking, ultrasonic, moulded-in, and cold pressed-in. Heat staking is a relatively low-cost process that lends itself well to automation, as multiple inserts can be pressed in at once. Ultrasonic insertion creates a vibration frequency that melts the plastic, and while it is comparable in speed to heat staking, it requires precise control and can create a larger process-affected zone. Cold-pressed inserts are highly economical as they are easy to install and typically do not require special auxiliary equipment.
Custom plastic injection moulding is used in many medical applications, including diagnostic instruments, blood separators, and laboratory equipment. Injection blow moulding can be used to create numerous types of stand-alone hollow parts, and is ideal for small, precision parts that require multicavity options.
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Frequently asked questions
They are called "rawl plugs", "wall plugs", or just "plugs".
There are various types of plastic inserts, including threaded inserts, heat staking inserts, ultrasonic inserts, molded-in inserts, cold pressed-in inserts, and compression limiters.
Plastic inserts are used to create strong joints and reusable threads in plastic components. They enhance the strength and durability of plastic parts by providing reinforcement, secure attachment points, wear resistance, and cost-effectiveness.
