Fastener Technology

Joining Lightweight Materials with Ultrasonic Energy MM-Welding

Bolting, riveting, welding, soldering, brazing, and fastening have always been the primary means of joining two materials – until now. MultiMaterial-Welding (MM-Welding®) is a new innovative technology that allows for error-free, lower-cost, and higher-efficiency joining of two dissimilar metals, composites, plastics, or other materials.

The MM-Welding® System continues Bossard’s never-ending pursuit of bringing its customers innovative fastening solutions. The result of a joint venture between the Bossard Group and SKion GmbH, the MM-Welding® System includes a series of stand-alone, operator-controlled fastening machines that leverage the latest in AI and smart solutions software. The ideal solution for creating strong fastened bonds between two dissimilar materials, the MM-Welding System® represents a giant leap forward in fastening technology, providing incredible savings and improved efficiency.

Most Common Issues with Manual Joining

While dependable, manual joining processes take time – with some joining and fastening processes more labor-intensive and costly than others. These processes are also prone to human error, have high assembly cycle times, and require more time for in-process and final QC inspection. In many cases, they involve designing and manufacturing customized assembly jigs and fixtures, which further increases costs.

Pre-drilling or punching holes, threading, and tapping, positioning fixtures, assembling various fasteners and either torquing or applying force to ensure proper assembly may seem simple, but these multistep processes are often anything but efficient. They are even more complicated when trying to join two different material types – such as metal to composite or metal to plastic.

Something more is needed.

Smart Manufacturing, Artificial Intelligence (AI) and Lightweight Materials

Today’s manufacturers rely on lightweight, high-strength metal alloys, composites, polymers, and plastics. Increased efficiency, reduced weight, lower cost, and improved performance drive the constant need to innovate with newer materials, formulations, and faster production processes.

With the increased reliance on smart manufacturing, the continued adoption of artificial AI, and the need to shorten product-to-market lead times with faster, more efficient designs and higher quality products, today’s manufacturers need an all-encompassing material-joining solution that shortens new design times, reduces assembly costs, eliminates errors and improves efficiency.

MM-Welding® is that solution.

The MM-Welding® System

The MM-Welding® solution addresses all the inefficiencies associated with manual assembly and joining processes. Relying on ultrasonic waves and friction, the MM-Welding® is a next-generation fastening solution that creates high-strength, durable bonds between two materials. Whether it is two dissimilar metals, metal to plastic, metal to composite, or two non-compatible polymers, the MM-Welding® system can create form-fit connections every time.

A solution that addresses today’s manufacturing needs, MM-Welding® includes intuitive AI, big data, and machine-learning features that provide endless simulations that dramatically improve rapid prototyping and design. Troubleshooting the assembly of two dissimilar materials can be done through the MM-Welding® solution’s software, helping to avoid costly delays in design and in-process assembly times.

The MM-Welding® smart solution software also allows for seamless, in-process, real-time quality control, eliminating manual QC inspection. From fully digitizing your entire production process, shortening design, and rapid prototyping, to using any fixture with any material, MM-Welding® is a revolutionary joining system that ensures an error-free, high-strength, low-cost joining solution with high repeatability.

  • Increased joining efficiency
  • Lower costs
  • Error-free
  • High repeatability
  • Shorter design times
  • High-strength, durable bonds between two dissimilar materials
  • AI, smart manufacturing, and fully digitized

Bonding Expanded Polypropylene (EPP) with MM-Welding®

A critical material relied upon by automotive manufacturers for car headliners, floor mats, and carpets within the cabin and trunk of today’s vehicles, EPP is a 100 percent recyclable multiple-layer, porous material. Possessing excellent impact absorption and strength-to-weight ratio properties, porous EPP is a temperature-resistant material with superior sound-deafening qualities and low water absorption properties. It is also a lightweight material that provides superior cushioning.

  • Excellent strength-to-weight ratio
  • Fantastic impact absorption properties
  • Temperature resistance (cold and hot)
  • Low water absorption properties
  • 100 percent recyclable
  • Excellent thermal insulator
  • Superior sound-deafening properties

Conventional Multi-Step Fastening Processes for EPP

Conventional fastening solutions typically include a labor-intensive process requiring various fasteners, multiple separate fittings, and press or friction fittings. These processes can often involve more than one operator working on different fastening locations for a single part. While improvements have been made over the years with conventional multistep EPP fastening, the result is a multistep process with higher cycle times and increased costs.

Not only are conventional EPP fastening processes labor-intensive and costly, but they are also prone to numerous human errors or process errors, leading to many unsecured joints and quality issues.

  • Multiple-step process
  • Labor-intensive
  • Prone to human error
  • Expensive
  • Inefficient
  • Costly

The MM-Welding® System: Increased Efficiency for EPP Bonding

The MM-Welding® System is a single-process solution that uses friction and ultrasonic waves to create a durable, exceptionally strong bond between two EPP materials. This eliminates all the waste, process errors, and high labor and fastener material costs associated with conventional EPP fastening processes.

By leveraging this single-process bonding solution along with the smart software and AI features within every MM-Welding® System machine, welders can dramatically reduce costs, improve quality, reduce errors, and ensure a stronger, longer-lasting bond between two EPP materials.

So, what are some of the stand-alone MM-Welding® System machines?

The MM-Welding® System Table-Top Machine

The MM-Welding® System Table-Top Machine is a manually operated table-top solution where the ultrasonic system can be configured on a customized table with different-sized dimensions. The solution allows the user to operate the machine by hand or with a foot switch. Extremely functional and easily moved and adjusted, the MM-Welding® System Table-Top Machine is ideally suited to welders who operate alone and need to bond different-sized EPP materials.

The MM-Welding® System X-Y-Portal Machine

Allowing for different programming options and multiple clamps, the X-Y-Portal Machine allows users to bond multiple different bonding or welding locations within a single operation, helping to drastically reduce cycle times while providing a superior bond. Nesting can be changed as needed while the feeding system’s noise housing ensures a quiet and seamless operation.

The MM-Welding® System Dedicated Machine

Dedicated Machines are the ideal solution for high-volume, low-cycle time EPP bonding applications. This customizable machine allows for bonding EPP at different angles, multiple locations, and various heights, making it the ideal solution for bonding parts with unique profiles and geometries. Incorporating the same noise-blocking housing as the X-Y-Portal Machine – but in a much larger envelope – the Dedicated Machine can be customized for multiple feeding and has the option of different-sized turntables.

The MM-Welding® System Robotic Machine

Seamlessly integrated into existing production and assembly lines, the MM-Welding® Robotic Machine is the ultimate in functionality. Able to bond or weld multiple materials, Robotic Machines provide an easy-to-use interface, can bond different-sized materials with various thicknesses, and require minimal adjustments to the production or assembly line.

An extremely compact, high-performance, low-maintenance machine, welders can easily access real-time production data and cycle time information, giving them near-instant feedback on all things production-related. This system is the ultimate in ultrasonic wave technology, efficiency, and bonding throughput with its ability to reduce costs, eliminate multiple processing steps, and improve product quality.

Optimized Fastening Solutions with Bossard

The MM-Welding® solution is but another example of Bossard’s continued drive to provide our customers with innovative, reliable, and proven fastening technologies and solutions to improve efficiencies and reduce costs.

Bossard is a well-recognized, established market leader in fasteners and fastening applications. Whether it’s standard or customized fasteners, Bossard has long been seen as a critical partner to manufacturers in multiple industrial and commercial markets. These fastening solutions are combined with Bossard’s real-time smart factory logistics solutions, helping companies better manage their B and C parts and consumables.

If you would like to learn more about how MM-Welding® can help you create a seamless, full-digitized manufacturing and product process, contact us now.

 

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Bossard
August 23, 2024
Lean Manufacturing, Fastener Technology
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Advantages of Bossard Kitting and Assembly Services

Bossard Kitting

Whether you’re a manufacturer looking to improve material flow, maximize shop floor space, and adopt lean manufacturing best practices, an e-commerce enterprise wanting to increase revenue while also reducing dead stock or slow-moving inventory, or a warehouse and distribution center wanting to optimize shelf and warehousing space while increasing inventory turnover, there are numerous advantages to product kitting.

Understanding how kitting and assembly solutions work for manufacturers versus how they work for e-commerce enterprises, warehouses, and distribution centers goes a long way to maximizing returns and improving efficiencies. Kitting is a specific process with its own set of procedures and those procedures depend largely upon the type of company that uses it.

Manufacturers Adopting Lean Manufacturing Best Practices

For manufacturers, the kitting meaning is different compared to other companies. In manufacturing, the kitting and assembly process is initiated by the customer’s purchase. The raw materials, parts, tools, and consumables needed to manufacture the finished product are derived from that finished product’s bill of materials (BOM).

The BOM lists every line item required to fulfill the customer’s order. Everything is placed within a bin as a single “kit” and provided to production. That kit then flows through various stages of production as it gradually moves from a semi-finished to a finished product. Employees don’t waste time visiting inventory storage for much-needed parts and consumables.

Kitting in manufacturing eliminates multiple forms of waste. It improves material flow, reduces the burden on inventory space, eliminates wasted technician/production employee time looking for essential parts, consumables, and materials, reduces inventory waste and consumable overuse, and acts as a fail-safe/error-proofing Poka Yoke solution during picking and assembly.

Kitting and Fulfillment in E-Commerce

In e-commerce and warehouse fulfillment applications, kitting allows companies to combine multiple in-demand products with less popular or lesser-known inventory items. Customers receive one kit of different products while the e-commerce enterprise increases sales while decreasing its inventory of slow-moving or dead inventory. Think of a brake assembly for an after-market automotive supplier; calipers, brake pads, and rotors can be included with additional hardware products like locking bolts, shims, seals, pins, and other ancillary support hardware.

The kit is marketed and sold as a single item – which often requires a single designated inventory SKU. Like manufacturers, e-commerce enterprises and warehouse fulfillment can free up valuable shelving and inventory space, reducing picking and packaging errors, and reducing per-unit shipping costs while providing the customer with increased value.

The best e-commerce enterprises borrow from lean manufacturers by creating streamlined warehouses with multiple lean packaging workstations where kitting specialists have instant and immediate access to each product. Inventory replenishment for these packaging workstations is handled by support employees.

For e-commerce, warehousing, and distribution centers using product kitting systems, order fulfillment times are drastically reduced while still being able to offer multiple inventory SKUs or kits to accommodate customized orders.

Bossard – Your Kitting and Assembly Solutions Provider

Fastener Solutions
Learn More About Kitting

Long recognized as a global market leader in fastener technology, Bossard combines its premium-quality fasteners with C-part management, logistics, and warehouse strategies and digital solutions that provide increased productivity and bottom-line savings. Regardless of whether you’re a manufacturer, e-commerce enterprise, warehousing fulfillment, or distribution location, our logistics and warehouse subject-matter experts can help you with unparalleled insight and guidance on adopting product kitting solutions.

To learn more about Bossard’s kitting and assembly solutions and how our cutting-edge digital logistics tools can maximize your business, contact us now.

 

 

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Bossard
August 16, 2024
Production, Lean Manufacturing, Supply Chain / Logistics, Fastener Technology, Total Cost of Ownership
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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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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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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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Fastener Finish: Platings and Coatings for Fasteners

Fastener Finish

The finish, or coating, is just as important as the design when you want your fasteners to last for the life of your product. If you want more information on the description below, please contact your local Bossard agent.

Factors to Consider

When you’re trying to decide on the correct finish, consider the following factors.

·         Safety. Improperly applied finish may make the fastener fail. A common failure point that can be introduced by finish is hydrogen embrittlement. Embrittlement reduces ductility and load-bearing because the metal absorbs too much hydrogen during the plating process. Choosing a dip-spin coating or Bossard’s ecosyn® tribological dry coating over using an electroplated finish can alleviate this risk.

·         Corrosion Protection. How long will the finish last based on its operating environment? The fastener requires a stronger coating if it endures very severe conditions that include saline solutions, cleaners, moisture, and collisions that produce abrasions, scratching, and denting.

·         Resistance to Handling Damage. How frequently will workers handle or use tools on the fastener? A softer and more brittle finish demands more care during handling and assembly.

·         Criticality of the Joint. What happens to the entire assembly if a joint becomes loose? Some finishes do not have known friction values. Avoid those finishes for fasteners on joints with consistent and repeatable clamp loads.

·         Functionality. Fasteners with small diameters and threads that have internal recess drives may leave too much coating material in the recesses or threads if the wrong finish is used.

·         Cost. Exotic coatings will increase the price of the fastener and the total cost of production.

·         Availability. Is the finish you want readily available? Or will it have to be special-ordered, which demands a greater lead time and more expense?

Common Finishes

If cost or time is a concern, rely on the following fastener coatings, which are easily available.

·         Electrodeposited (Commercial) Zinc. This finish is inexpensive, works under mild to moderate conditions, and is moderately resistant to handling damage. It has no problems with recess fill or threads. However, its friction is harder to control and it risks hydrogen embrittlement at high strengths.

·         Electrodeposited Zinc Nickel. This finish functions well under severe to very severe conditions and has good resistance to handling damage. It is also free of issues with recess fill or threads but has a high cost, difficult-to-control friction, and is not as available as commercial zinc. The chances for hydrogen embrittlement are lower but still existent.

·         Mechanical Zinc. With no hydrogen embrittlement risk, this finish features moderate resistance to handling damage and mild to moderate corrosion. It is not recommended for threads because of poor coverage in recesses and holes. The cost is medium to high while availability ranges from medium to low.

·         Zinc Flake. Hydrogen embrittlement is not a risk for this finish that protects against severe to very severe corrosion and has high friction control. It is moderately resistant to handling damage but is not recommended for any fasteners with an internal drive. The cost is moderate.

·         Hot Dip Galvanized. Protecting against severe to very severe corrosion, this moderately-priced coating has excellent handling-damage resistance and moderate cost. However, friction is difficult to control and it is not recommended for threads less than M8 or with an internal drive. The risk for hydrogen embrittlement is low.

·         Epoxy Electrocoat. This coating has no hydrogen embrittlement risk, works under severe to very severe conditions, is moderately resistant to handling damage, and is excellent at controlling friction. It has no problems with recess fill or threads at M4 or more. But it is pricey.

 

·         Tribological Dry Coatings. A solution for mechanically stressed fastening elements and components, such as screws, nuts and washers. The coating is a non-electrolytically applied thin layer with integrated lubrication properties and additional corrosion protection.

Bossard
July 08, 2022
Fabricated Metal Products, Fastener Technology
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