Author Archives Bossard

Helicoil Wire Inserts for Modern Manufacturing

image of a Helicoil insert

In the dynamic world of manufacturing and engineering, fasteners play a crucial role in ensuring the integrity and longevity of assembled components. When it comes to threaded connections, issues like thread damage, wear, and stripped threads can pose significant challenges. This is where Helicoil inserts come to the rescue, offering a reliable and effective solution for thread reinforcement.

While widely known for its use in stripped thread repair for bolted joints, threaded inserts also allow for a strengthened threaded hole in softer materials like wood, plastic, composite sandwich panels, and softer metals such as aluminum. This attribute gives helicoil inserts an important role in today’s modern manufacturing with 3-D printed parts, lightweighting, composites, and increased use of plastics.

What are Helicoil Inserts?

Helicoil inserts are precision-engineered coils of wire with a diamond-shaped cross-section. These inserts are designed to be installed into a tapped hole, providing a stronger and more durable threaded connection. This is especially useful where you need to have a durable, reusable thread that is stronger than the surrounding material or in softer metals prone to galling.

Helicoil and 3-D Printed Manufacturing

3-D printed parts require post-processing before they are ready for assembly. In addition to the usual finishing techniques of sanding and smoothing, metal inserts should be used where bolted joints are required. This adds durability to your threaded hole to allow for repeat assembly and disassembly as well as providing clean engineered threads.

Helicoil and Composite Panels

Core Blocking allows Helicoil inserts to be used to create a solid mounting point in composite honeycomb and skinned core panels by installing a solid block of material into the panel core to accommodate a drilled hole and helicoil insert.

Suitable for high-volume production

Helicoil offers power tools and strip feed options to speed up assembly with precision in production environments. These tools can be configured for hand-held operation or mounted for repeat accuracy during assembly.

Threaded inserts have evolved from their humble beginnings in the aerospace industry and their utility has far outstripped their reputation in thread repair. With a wide range of inserts and coated options available, Helicoil has an insert for your application. The Assembly Technology Experts at Bossard are more than happy to discuss threaded inserts in greater detail. Contact us to find the right fasteners for your application at ProvenProductivity@bossard.com.

 

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Bossard
December 20, 2023
Production, Fabricated Metal Products, Quality Practices, Fastener Technology
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Fasteners in the Automotive Industry: Innovations and Trends

There are thousands of fasteners used in the manufacturing and assembly of a single automotive vehicle. Some fasteners are applied manually by technicians while others are installed with pinpoint accuracy by automated robotics, equipment, and machinery. Here is a list of some of the most recent innovations and trends concerning automotive fasteners.

Composite Material Fastening

The automotive industry is constantly on the lookout for lightweight, durable, strong, impact and fatigue-resistant materials. This never-ending pursuit is all about fuel efficiency. Lightweight composite materials mean lighter vehicle frames, better gas mileage, and thermal management.

Joining composite material does not come without challenges.  The fibrous and laminate nature of such materials makes traditional mechanical fastening difficult without fatiguing or cracking the composite.  Until recently, adhesive has been the go-to for the joining of composites but recent advancements in Bossard’s fastener technology allow embedded mechanical fasteners into composite panels.  This can be a huge benefit when considering composite to metal or substrates where adhesive just won’t bond.  Another benefit of using a mechanical join would be for applications where there is a need for repeat access or repair.

Multi-material designs can benefit from Bossard’s MM-Welding® technology by creating strong mechanical connections in porous, honeycomb, laminate, and injection molded components often found in automotive applications.

The Rise of Plastic Fasteners

Plastic is another lightweight but durable material used by automotive manufacturers. Lightweight plastic fasteners are less expensive than composite, steel, and other materials. One reason for their low cost is that the plastic injection molding process produces less waste compared to other conventional machining and manufacturing processes.

Prices are also lower because of lower labor costs as molding machines can run 24/7 with minimal supervision. Plastic fasteners like washers, pins, and spacers don’t have issues with corrosion and certain thermoplastic resins have a high tolerance for heat, humidity, chemical exposure, extreme weather, and corrosive operating environments.

New Shapes, Sizes and Configurations

Fastener manufacturers are constantly having to come up with new fastener designs to keep up with the speed of automotive innovation. This includes designing fasteners with different shapes, sizes, configurations, and geometries. This constant push for new designs is driven largely by changing automated assembly equipment and machinery.

The lean manufacturing and continuous improvement processes of the automotive industry force the entire supply chain to innovate. Automotive manufacturers are always looking to reduce assembly and production cycle times. This constant pursuit means fastener companies must ensure that each generation of fastener is stronger, more durable, and more reliable than the last.

The Need for New Permanent Fastener Designs

With the further adoption of electric vehicles, the automotive industry is gradually moving away from semi-permanent joints. This is due in large part to the increase in electrical vehicle production where manufacturing, assembly, and service requirements differ greatly from conventional gas-burning cars.

While it’s not uncommon for combustion engines to be removed from cars for repair, servicing, and refurbishment, this is a less likely outcome with electric engines. Electric cars have engines that are permanently in place and not designed to be dismantled or removed. Properly securing the parts and integrated assemblies within electric engines requires the design of robust permanent fasteners.

A Constantly Changing Industry

The automotive industry will also demand more flexibility from designers as they push for more uniformity among internal and external fastener designs. This means designers must be open to reducing inventory skews by designing more universal fasteners for wide-ranging automotive applications.

If you would like to learn more about these latest innovations, contact us now.

Bossard
November 10, 2023
Transportation, Fastener Technology
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5 Common Mistakes to Avoid When Choosing Fasteners for Your Manufacturing Project

Hardware Assortment

It’s not uncommon for manufacturers to overlook the importance of incorporating high-quality fasteners within their product designs. Whether it’s choosing nuts, bolts, screws, washers, anchors, or rivets, these hardware devices are critical for affixing two or more parts, materials, or objects. Here are five common mistakes to avoid when choosing fasteners.

1. Choosing Price Over Quality

It’s easy to get enamored by the potential savings of using low-priced fasteners. Reducing the costs of new product designs increases profit. Unfortunately, the savings on low-cost fasteners are quickly eroded with longer assembly cycle times in production. Even if the fasteners pass the final QC inspection, it’s more than likely they’ll fail in the field once the customer uses the product.

2. Using the Wrong Fastener for Your Design

Using the right fastener in design is critical to ensuring the integrity, strength, rigidity, and durability of your finished part. That selection must be based on the types of materials you’re using and the types of parts or sub-assemblies you’re joining or connecting. In many instances, it’s a question of product safety. Using the wrong fastener or wrong fastener material can make your joints susceptible to cracking, bending, or buckling.

3. Dissimilar Metals in Your Bolted Joint (Galvanic Corrosion)

Galvanic corrosion occurs when two different metals are exposed to water. One metal becomes the reducing electrode (anode), while the other becomes the positive electrode (cathode). These two create an electrochemical reaction that eventually leads to galvanic corrosion. This is a common occurrence for finished goods exposed to elements like moisture and humidity where the fastener material is different from the base material.

4. Incorrect Torque

In layman’s terms, incorrect torque refers to either over-tightening or under-tightening fasteners. The goal is to find the ideal amount of clamping force to ensure the joints or parts remain secured without breaking, cracking, or failing. When the tension is too high the fasteners become stressed and can tear, rip, or break. When the tension is too low, excessive vibration leads to the fasteners becoming dislodged or loose.

5. Wrong Grade of Material

Fasteners can be made of plastic, composites, brass, steel, titanium, aluminum, chrome, carbon steel, etc. However, choosing the wrong grade of material can lead to your product’s premature failure. When choosing your fastener’s grade, think about the grade’s mechanical properties in terms of its tensile, fatigue, and shear strength.

Aside from the grade’s mechanical properties, it’s also important to understand how that material reacts under different environmental and operating conditions. Industrial finished goods are often exposed to corrosive environments. Without the proper coating, fasteners can easily corrode. Galvanized, nickel-plated, brass, and zinc-plated are just some of the coating options that help to protect fasteners from corrosion.

Making the Right Choice

Don’t make the all-too-common mistake of glossing over fasteners in your design. Use low-quality hardware or assume that all fixtures are the same, and a failure is more than likely. The right hardware ensures your non-permanent joints remain intact. In the end, it’s about the integrity of your finished good and your company’s reputation.

 

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Bossard
September 22, 2023
Production, Fastener Technology
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The Role of Fasteners in Sustainability

sustainability in manufacturing

Sustainability has become an increasingly important issue in manufacturing as the global community seeks to reduce its carbon footprint and protect the environment. One aspect of sustainability often overlooked is the choice of fasteners used in manufacturing.  Fasteners such as bolts, screws, and nuts are essential components of many products, and choosing environmentally friendly options can have a significant impact on the sustainability of the manufacturing process.

Ensuring your suppliers are in compliance with RoHS/REACH is a good baseline start to bringing sustainability to your manufacturing.  RoHS bans the use of certain substances used in the making of electrical and electronic equipment such as lead, cadmium, and hexavalent chromium.  REACH places responsibility on the industry to be transparent on its use of chemicals in manufacturing and report the properties of chemical substances to a central database.  Bossard is actively working with our manufacturers to offer products that are in compliance with the European Union Environmental Directive and constantly monitor environmental RoHS/REACH directives.

One option for sustainable fasteners is to choose environmentally friendly coatings and fastener finish.  A clean and environmentally friendly coating Bossard offers is a line of Tribological dry-coated fasteners.  This type of coating is a non-electrolytically applied thin layer with integrated lubrication properties, protection against contact corrosion, and no risk of hydrogen embrittlement further saving on the potential for waste.

Additionally, it is essential to consider the end-of-life of fasteners when choosing environmentally friendly options. Fasteners that can be easily disassembled and reused or recycled are preferable to those that are difficult to disassemble or cannot be recycled.  For example, stainless steel fasteners are a great choice to consider due to corrosion resistance, no additional finish requirement as well as ease of recycling.

Finally, choosing fasteners that are locally sourced can reduce the environmental impact of transportation. Sourcing fasteners from local suppliers reduces the distance that the products need to be transported, reducing carbon emissions and fuel consumption.

In addition, tracking usage over time by using big data and real-time analytics can also aid in procurement on an optimized schedule further reducing energy overhead in transport or storage.  Analytics can also eliminate wastage due to excess inventory.  Bossard’s ARIMs platform and Smart Factory Logistics can provide you with the data to optimize your C-parts procurement plan and aid in sustainability efforts.

In conclusion, choosing environmentally friendly fasteners is an easy way to make a significant impact on the sustainability of the manufacturing process. By choosing fasteners made from durable materials, prioritizing disassembly and recyclability, smart procurement planning, and sourcing locally, manufacturers can take an important step towards a more sustainable future.

 

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Bossard
April 28, 2023
Fabricated Metal Products, Fastener Technology
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The Hidden Cost of Fasteners

Fastener TCO and the 15/85 rule

You may be familiar with the concept of TCO (Total Cost of Ownership), but did you know you can apply a TCO model to fasteners?  Savvy decision makers apply TCO to analyze the hidden cost of equipment or services beyond the initial purchase price.  You can also apply this model  to reveal the direct and indirect cost of fastening in your manufacturing.

Bossard’s 15/85 rule is a concept used to estimate the total cost of ownership (TCO) of fasteners. The rule suggests that the cost of the fastener itself accounts for only 15% of the total cost, while the remaining 85% is due to indirect costs associated with the fastener.

The Rule of 15/85 Explained

The 15% cost includes the purchase price of the fastener, transportation costs, and any other direct costs associated with the acquisition of the fastener.

The remaining 85% of the cost includes indirect costs such as assembly time, installation costs, quality control, engineering, internal handling, and inventory management costs. These indirect costs are often hidden or overlooked, but they can have a significant impact on the overall cost of your assembly.

By taking into account both the direct and indirect costs, Bossard’s 15/85 rule highlights the importance of selecting fasteners not only on purchase price but also functionality (the ability to simplify a bolted-joint problem), high quality and reliability, ease of installation in assembly, and partnering with a value-add partner such as Bossard to help you tackle your indirect cost to reduce the overall cost of ownership.

Bossard’s Full-Service Solution

At Bossard, we take a holistic, full-service approach to helping our customers find the right fastening solution and improve productivity, all the while helping you to reduce your fastener TCO.  The following range of Assembly Technology Expert and Smart Factory Logistics services can help you tackle that hidden 85%.

  • Development and Design: Bossard’s Expert Design Service helps customers at the forefront of new product design and development by providing critical consulting and engineering insight into the ideal fastening solution.
  • Procurement: Having the right fastener at the right time reduces inventory counts and costs. Our customers rely upon the Bossard team to help identify the right fastening solution from a rolling inventory of over 200,000 different product SKUs.
  • Logistics and Handling: Bossard’s Smart Factory Logistics help companies manage their inventory in real-time with Smart Bins and Smart Labels in the warehouse and at point-of-use.  Helping you minimize waste, lower excessive inventory counts, and reduce downtime.
  • Ordering and Storage: Our interactive supply chain platform (ARIMS) improves customer supply chain efficiency and predictability with real-time analytics, metrics, and data.  Bring demand planning to your C-parts and have inventory when you need it.
  • Quality Assurance / Testing: Bossard can support your Quality Assurance and Design Engineers through its worldwide network of Bossard ISO/IEC 17025-accredited test laboratories. Every state-of-the-art Bossard test laboratory has the most accurate measuring and testing equipment to assure customers are meeting standards and specifications.
  • Kitting and Assembly: Bossard offers light assembly, labeling and kitting services that help manufacturers speed up and optimize assembly.

Partner with Bossard to tackle the visible and invisible cost of fasteners in your manufacturing through supply chain optimization, engineering, expert test services, and global reach and reduce your TCO in fastening.

If you need help reducing your TCO or need some expert guidance on fastening solutions, contact us now.

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Bossard
March 24, 2023
Total Cost of Ownership
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Mechanical Engineering Calculators you Need to Add to Your Toolbox

Mechanical engineer design

Your choice of fastener has a big impact on Design for Manufacturability and bolted joint design. Fastener selection requires careful planning to avoid product failure and manage quality and cost of your assembly.  With Bossard’s readily-available inventory of over 200,000 different screws, nuts, washers, pins, rivets, threaded inserts, screws, clip fasteners, surface bonding fasteners, clinching solutions, and multiple other industrial accessories, taking advantage of the Bossard tools and calculators below can help you choose the right one.

As a mechanical engineer, you have a lot to consider in your design.  Material to be joined, Clamp load, Stress, Temperature, Shear, Torque, Coefficient of friction, Corrosion – Solving any of these design problems can be made a lot easier using multiple Bossard calculators and converters. These ready-made tools are heavily relied upon by engineers, technicians, designers, project managers, and students and are outlined below.

Bossard Online Converters

The following Bossard online converters are used to convert various units of measure.

  • Length Converter: This converter accesses upwards of 68 different units of measure and converts inches, centimeters, meters, miles, KMs, feet, yards, etc.
  • Torque Converter: Calibrated torque wrenches are essential in some industries. This tool converts different torque values such as kilonewton meter, newton meter, newton centimeter, kilogram-force meter, once force inch, etc.
  • Pressure Converter: Bossard’s pressure converter converts various pressure units such as PSI, bar, millibar, pascal, ton/square foot, pound/square foot, etc.
  • Force Converter: Another simple-to-use converter that can convert newton, meganewton, kilonewton, dyne, kilogram-force, ounce force, etc.
  • Metric to Inch Fastener Converter: Ideal solution for converting metric to inch fastener forces.
  • Hardness Converter: Ideal tool for hardness-to-hardness measurement (Rockwell, Brinell, Vickers) and hardness-to-tensile strength conversion of cast iron and low-alloy steels.

Online Calculators for Design/Production

Bossard offers a comprehensive line of online calculators for technical design and production requirements.

  • Metric Thread Profile Calculator: This calculator is based on ISO 965-1:1998, ISO 68-1:1998, and ASME B1.13M-2005, allowing you to calculate metric thread geometry.
  • Pilot Hole Design for Metric Thread Formers: DIN 7500:2009 calculator for calculating hole size for metric thread forming screws.
  • Selection of Material and Coatings for Corrosion Protection: Ideal for any situation where choosing protective coatings is critical to corrosion protection.
  • Drill Hole Size for Tapped Threads: Instantly calculates the proper tap drill size for screws.
  • Pilot Hole Design for Tapping Screws: Calculates the ideal hole diameter for tapping screws.
  • Pilot Hole Design for ecosyn®-Plast: Calculator determines boss geometry for thermoplastic resin types for ecosyn®-plast.
  • Tolerances for Shafts and Holes: Easily calculate hole and shaft tolerances.

Online Calculators for Technical Design

  • Estimation of Bolt Size and Property Class: Calculator to determine the required diameter and property class.
  • Disc Spring Calculator: DIN-2093 Calculator for disc springs with geometry, values, and properties.
  • Cost Savings Calculator: Insightful tool allows you to calculate activity costs and uncover potential savings.
  • Thread Engagement Length Calculator: Simple calculator for calculating thread engagement for blind-hole and through-hole to determine sufficient thread engagement length.
  • Torque and Preload With Nut Factor: Uses basic formula of T = D*K*F to calculate tightening torque and preload with nut factor for screws (inches).
  • Torque and Preload with Nut Factor and Tool Accuracy – Inch: Allows you to calculate tightening torque and preload using the formula T = D*K*F mean.
  • Torque and Preload with Nut Factor and Tool Accuracy – Metric: Same tool as above but in metric.
  • Torque and Preload with Friction Scatter: Calculator based on VDI 2230: 2014 that calculates tightening torque for hex and socket head screws.
  • Torque and Preload for Customized Geometry and Material: Another calculator based on VDI 2230:2014. This one calculates pressure, preload, and tightening torque for socket head and countersunk screws by accounting for multiple head shapes, materials reduced, chanks, and hole champers.
  • Torque and Preload Calculator: Yet another calculator incorporating VDI 2230:2014, capable of calculating tightening torque, surface pressure, and preload values for head and socket head screws.

Each of these tools is accessible to all and free to use under the terms as set forth under Imprint. If you need any guidance, help, or have questions about a new project of yours, contact us today and speak with a Bossard Assembly Technology Expert.

 

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Bossard
February 24, 2023
Tools
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What to Know About Fastener Certification and Compliance

Fasteners play a critical role in holding your assembly together and can affect many aspects of your product lifecycle.  Joint strength, manufacturability, performance in various environments and even maintenance over the assemblies lifespan are all factors directly impacted by fasteners.  Unfortunately, fastener performance is affected by its quality of raw material, manufacturing and even plating.  To that end, many manufacturers rely on fastener certs and proof of compliance to ensure a fastener defect does not become a defect of your whole assembly. 

Importance of Fastener Certification and Validation

The following fastener conformance, tests and reports can be requested to ensure quality of your manufacturing and enforce standards.

The Fastener Quality Act

(FQA) in the United States makes it illegal to falsely represent fasteners’ chemical and mechanical properties by misrepresenting or altering certificates of conformance, material test reports, inspection reports, and all records attesting to a fastener’s characteristics and performance. Originally meant as a sweeping reform to combat an influx of inferior, mis-marked and counterfeit parts during the 1980’s, the act is now limited to hardened and grade-marked high strength fasteners.

Restriction of Hazardous Substances

Commonly known as RoHS – is a European directive adopted in 2003 that prohibits using hazardous heavy metals in manufacturing components for industrial and commercial use. These include metals such as mercury, lead, hexavalent chromium, and cadmium, in addition to thermoplastic resins like polybrominated diphenyl ethers (PBDE), phthalates (DEHP), and polybrominated biphenyls (PBB), etc.

The Registration Evaluation Authorization and Restriction of Chemicals

(REACH) regulation is another European initiative launched in 2006 with the aim of restriction certain chemicals and substances in manufacturing. This regulation was enacted to protect the environment and everyday consumers from harmful substances and noxious chemicals.

CoC – Certificate of Conformance (or Compliance)

The fastener manufacturer provides a CoC to ensure the fastener meets industry or customer specifications.

MTR – Material Test Report (also known as – Inspection Report, Test Report, Chem-Phys Report)

A Material Test Report – often referred to simply as a “Mill” Test – is a document that attests to a given material’s mechanical and chemical properties. It is viewed as a quality document or certified record that the material and part meet the required specifications.  

Plating Certification

A plating certification – or plating cert – states that the plating process successfully applied a coating or layer of metal to a given surface, helping to protect it against corrosion, scratches, and extreme environments.

ISIR – Initial Sample Inspection Report

An ISIR report is a critical part of following established initial sampling processes. These processes are sometimes required by customers and are used to validate the fastener’s quality and use in production.  

PPAP – Production Part Approval Process

A standard requirement in the automotive and aerospace industry, the Production Part Approval Process is a procedure listing 18 steps to ensure repeatability, conformity, and consistency in fastener manufacturing.

DFARS Compliance: The Defense Federal Acquisition Regulations Supplement

DFARS compliance is an absolute must for defense contractors. Compliance provides guidelines and restrictions governing raw material selection to minimize dependence on foreign material sources.

Going beyond the standard – Full-Service Quality Solutions From Bossard

In addition to providing fastener certs and manufacturer declarations, Bossard can provide customized quality assurance with our Expert Test Services.

Dedicated towards the testing of mechanical fasteners, our ISO/IEC 17025 accredited test laboratories are staffed with qualified engineers and state-of-the-art test equipment.  If you require failure analysis or independent confirmation of product quality, Bossard Expert Test Services can provide you with a sound basis for making informed decisions regarding your fasteners and ensure high quality products.

 

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Bossard
January 27, 2023
Fastener Technology
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Importance of Choosing The Right Fastener for Design for Manufacturing and Assembly (DFMA)

The Next Big Thing in the Product Design Process

Selecting the best fastener for your application can be tough. To make matters worse, not all fasteners are created equally. Choosing the correct fastener design, finish or material type can make all the difference in assembling a quality product.  As such, it’s imperative to choose the right fastener as early on in the design process as possible and this sentiment outlines the notion of Design for Manufacturing (DFM). Let’s take a closer look at the importance of choosing the right fastener and why DFM principles can serve as a guiding light in the journey. 

What Is Design for Manufacturing?

Design for Manufacturing or Design for Manufacturing and Assembly involves optimizing the design of a product for efficiency in assembly, cost and quality.  To embrace DFM, you must engineer or design in a component or bolted joint with these principles in mind during the product’s design stage.

The alternative is to design the product and then choose the fastener. This less efficient practice can lead to inefficient assembly, weak joints or the necessity of special fasteners, which are not readily available or common. Using special fasteners can also:

  • Greatly increase the cost of production
  • Reduce the lifespan of the product
  • Cause product malfunctions
  • Lead to product performance issues

Implementing Design for Manufacturing and Assembly Principles in Fastener Selection

Design for Manufacturing and Assembly should occur early in the development of a product during the design phase. When using this discipline, manufacturing will become efficient and cost effective, since choosing the right fasteners can later define the assembly process and reduce tooling.   While the exact DFM workflow can be tailored to the unique application and part being designed, a few general DFM principles are:

  • Design fasteners and objects for fast and efficient assembly.
  • Work to standardize components and materials to save money.
  • Achieve design simplicity by reducing the number of parts and complications.
  • Minimize the number of manufacturing operations required on fasteners during assembly.

Why Are DFM Principles Important in Fastener Selection?

Design For Manufacturing represents the evolution of product design and can be leveraged to produce products more economically and at higher quality.  No other component in the assembly process can have as broad of an impact on your DFM as choosing the right fastener.  A few key benefits and reasons why fastener selection should be a core focus of your DFM planning:

  • More cost-effective production.
  • Faster time-to-market.
  • Reduction of the product development process.
  • Production will be up to speed quicker.
  • Components can be combined to reduce assembly steps and the number of parts.
  • It detects and removes faults or mistakes.
  • Delivers a higher quality of the product because the design can be enhanced and refined at each stage.
  • It can create a safer working environment.

Contact Bossard for Fastener Selection Assistance 

Fasteners are engineered to hold two parts together. With this in mind, it’s best to avoid adding “higher responsibilities” to simple fasteners and work to achieve design simplicity. A few additional basic rules for choosing the best fasteners are:

  • Fasteners must always be equal to, or better than, the assembled parts.
  • Bolted joints may never be points of weakness.
  • Assembled fasteners should always be controllable as well as exchangeable.

In the end, making fasteners a top priority in the design process by embracing Design for Manufacturing and Assembly principles can unlock all of the aforementioned benefits and more.  Want to implement DFM for your assembly and don’t know where to start?  Bossard’s Assembly Technology Expert Services and Engineers are available to help.

For help with choosing the right fastener for you or if you have other questions about fastener technology, contact us at ProvenProductivity@bossard.com.

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Bossard
December 09, 2022
Production, Supply Chain / Logistics, Fabricated Metal Products, Fastener Technology
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4 Key Types of EMI/RF Shielding Solutions for Electronic Applications

EV Powertrain

Anytime electromagnetic waves are flowing, your most important devices and the lives of those who rely on them could be at risk. Electromagnetic interference (EMI) and radio frequency (RF) interference are both types of interference that can be extremely hazardous to the performance of electronic equipment. To prevent this, the experienced engineers of Bossard offer coordinated systems that can help establish and amplify your EMI defenses. 

We offer a vast range of EMI/RF gaskets and shielding products from industry-leading brands. Because we offer experience in an array of industries, including Electric Vehicle, Aerospace, and Telecom, we can help protect your electronic devices with a wide selection of metal gaskets, absorbers, sealing gaskets, and even fabric over foam conductive shielding. Let’s take a closer look at some of our most popular solutions. 

A Full Line of EMI & RF Absorbers

Absorbers are magnetically loaded sheets that boast a high loss at specific frequencies. Easy on any budget and fully customizable, most RF absorbers fight reflectively using lightweight and flexible polyurethane foam. Bossard offers a full line of broadband microwave absorbers designed for both military applications and commercial applications. Our microwave absorbers are often used in:

  • Antenna systems
  • Railroad and Mass Transit
  • Medical Equipment
  • Electronic cabinets
  • Electric Vehicle
  • Avionics
  • And more

Browse all EMI/RF absorbers.

EMI Shielding & EMI Gaskets

While EMI gaskets were previously reserved for radio communication and military equipment, they are now found in an array of electronic equipment. Most notably in the emerging EV market where densely packed electronics and sensors need to be protected from crosstalk.  EMI gaskets function by creating a conductive path along seams and other openings in an electronic enclosure. The covering works to block possible differences across the shield surface and establishes a smooth flow of current.

In the most simple sense, EMI gaskets plug all holes in a piece of equipment to prevent electromagnetic signals from interfering with the operation. At Bossard, our EMI gaskets are ideal as all-purpose contact strips for electrical enclosures. Best of all, EMI gaskets do not require adhesives and fasteners. 

Explore all EMI shielding and EMI gaskets.

Foam-over-Fabric Gaskets

Foam-over-fabric (FoF) EMI gaskets boast high shielding attenuation and conductivity. FoF gaskets are perfectly suitable for applications that require low compression force. The FoF profiles are offered in a UL 94V0 flame retardant iteration that boasts a high level of shear resistance and abrasion resistance.

Common applications for FoF EMI gaskets include grounding and shielding automotive electronic equipment seams and apertures. At Bossard, we offer a vast range of different shapes and thicknesses of FoF gaskets to meet any design need. Custom shapes and sizes can be engineered to meet the unique requirements of the application, along with the addition of special-purpose pressure-sensitive adhesives and more.

Learn more about foam-over-fabric gaskets. 

EMI/RF Sealing Gaskets

As the name suggests, the most important function of EMI/RF sealing gaskets is sealing. These gaskets are designed to protect a vast range of electronics from electromagnetic interference. And certain models of EMI/RF sealing gaskets can even establish a liquid-tight seal. In either case, sealing gaskets are available in a vast range of types and styles, including:

  1. Push-On Sealing Gasket by Essentra
  2. The stainless steel Liquid Tight Sealing Gasket by Thomas & Betts

Learn more about different Sealing Gaskets.

Contact Bossard Today

Proper EMI design considerations are vital for almost any electronic device. There are a myriad of EMI sources and receptors in the broader environment in which the device must operate. Fortunately, the engineering experts at Bossard can help. We offer decades of experience in engineering and helping manufacturers mitigate the harmful impacts of EMI and RF interference with their respective devices. 

Contact Bossard today to amplify your EMI/RF interference protection. 

 

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Bossard
August 12, 2022
Electronic & Electricals
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Fastener Head Style

Fastener Head

When you start looking for fastening solutions at Bossard, you’ll notice that we carry a diverse variety of screws and bolts. One way to distinguish one from the other is through the type of head that they have. The following are some of the most common styles. While head styles do have a specific purpose in creating a mechanical joint, you can find out which is most appropriate for your assembly by contacting your local Bossard agent.

Countersunk Screw Heads

If a screw has angles under the head, it demands countersinking to prevent the wood from splitting during drilling or other force. Countersunk screw heads include the following:

  • Flatheads sit flush against the surface of the material being screwed, which makes for a cleaner appearance and prevents anything from being caught on them. If you’re fastening wood or plastic laminate components, a screw cover hides the head completely.
  • Roundheads, which are also called raised screw heads, use angles similar to that of flat heads, so they require countersinking. Their domed heads look decorative, so they are used where appearance is important, such as for switch covers. Roundheads that are designed for a socket drive are called button heads.
  • Bugle heads reduce damage to material by spreading the joint stress over a broader surface than flatheads. They’re used mostly for plasterboard, wood decking, and drywall. They are self-drilling, which means they compress the surrounding drywall and paper to create a countersunk hole during drilling.

Both flat and round heads generally demand a pilot hole, which is a small hole drilled to guide the main screw in.

Non-Countersunk Screw Heads

Non-countersunk screw heads are the most common type and have flat surfaces under the head, which avoids countersinking. They are fully exposed above the surface of the material being screwed.

  • Domed heads have a rounded head that adds aesthetic appeal to a product.
  • Button heads also have a round design but are used with socket-driven screws and Torx drive recesses.
  • Pan heads are the most common type of flat-bottomed screw. They are versatile enough to substitute for other round styles.
  • Fillister heads use a slightly rounded top with a small diameter on high cylindrical sides. Their higher profile requires a deeper drive slot than round or pan head screws.
  • Truss heads are wider and slightly rounded to produce a lower profile and larger bearing surface. They are useful for sheet metal joints.
  • Hex heads allow for more torque and demand a socket or wrench for installation.
  • Socket cap heads require socket drive recesses for flush installation against the surface. They deliver a smooth appearance despite being non-countersunk.
  • Square heads are found in bolts and screws. They require a wrench for installation.

Bolt Heads

Some bolt heads have shapes that are similar to screw heads, such as flat, round, truss, and hex. Unique types include the carriage bolt, which uses a rounded dome with a square underside, anchor bolts, which do not contain a head, and J and U bolts, which look like their namesakes.

 

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Bossard
August 05, 2022
Fastener Technology
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