Fastener Technology

The Next Big Thing in the Product Design Process

The Next Big Thing in the Product Design Process

The fasteners used in your product are critical and can’t be understated. They literally hold your product and/or process together. As such, it only makes sense to design your product focusing on the fasteners from the very beginning. Fortunately, you have a team of experience, support, and guidance at Bossard.

As the leading name in fasteners and fastening technologies, Bossard offers decades of in-depth knowledge on different assembly methodologies, technical resources, and fastening joints. Regardless of the application, we will work to create fasteners and solutions that are the ultimate game-changer for your success. Let’s take a closer look at how Bossard can help elevate your new product development strategy.

Better Design + Better Development = Better Products

We get it — designing a high-quality, safe product while facing increasing competition and time constraints is a challenge. And while the functionality of a fastener may seem to be trivial, the requirements are especially demanding.

The Bossard Expert Design team can help elevate the quality of your product with materials recommendations and optimized conditions for assembly. On the other hand, we can assist with advanced prototyping based on our extensive knowledge of CAD big data and 3D prototyping. When you partner with Bossard, you’ll be privy to a unique suite of benefits and advantages:

  • Superior in-place costs: select the most ideal fastening design.
  • Reduced cost of production with streamlined, faster assembly processes.
  • Lowered life cycle costs from having the best quality of fastener from the beginning.

Access Assembly Technology Expert

Bossard application engineers are full of process optimization, continuous innovation, and efficiency knowledge. When you partner with us, you’ll open the door to each of these factors to gain a competitive edge in manufacturing.

The Bossard Three-Stage Methodology

Using an innovative three-stage methodology centered around slashing costs and reducing production time, we guide each project from product concept to production.

  1. From the beginning, we incorporate a focus on fastening joints to ensure perfect products.
  2. We will work to fine-tune your fastening process to perfection with proven methodologies, smart sensors, and industrial analytics.
  3. At Bossard, we believe in sharing our expert knowledge with those we serve. We are proud to be experts in the science of fastening.

Assembly Technology Expert Services

From beginning to end, our Assembly Technology Expert specialists will work to help you achieve the most intelligent solution for all fastening challenges. A few key services we offer include:

Ready to learn more? Contact Bossard today at ProvenProductivity@bossard.com.

 

 

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Fasteners for Train Bogie Design

Fasteners for Train Bogie Design

Bossard is a leader in fastening solutions for an array of industries, including railway applications. As a leader in the industry, we offer a range of solutions engineered for the reliability, high speed, and promptness required to help make trains operate faster and more economically.

Because we understand the necessary trends and requirements of the industry, we have the proven ability to provide fasteners that meet or exceed the highest safety and quality standards. We provide solutions that help increase efficiency and productivity. We offer exclusive fastening solutions for all parts of any railway system, including

  • Supply Units
  • Rail Vehicle Body
  • Bogie
  • Energy Supply
  • Interior

Let’s take a closer look at key fastener solutions offered for the bogie.

Key Requirements for Bogie Fastening Solutions

No matter the type or size of the train, the chassis or framework that carries the wheel set is a critical component. The primary requirements of the bogie are operating maintainability, reliability, and traveling comfort throughout the suspension and damping system. In addition to several other desirable attributes, bogie fasteners must be:

  • Resistant to extreme temperature changes
  • Vibration-proof
  • Resistant to corrosion
  • Able to maintain clamp force of assembly

Bossard Offers Tailored Bogie Fastening Systems

Bossard offers a range of different fastening systems and solutions for the bogie. Some of our top bogie fastening systems are listed below.

Bogie Lock Washers

Bogie lock washers are designed to deliver exceptional security through friction and mechanical locking. Our bogie lock washers are:

  • Suitable for coated and sensitive surfaces
  • Boast no loosening and minimal loss of pretension force
  • Ribbed for higher resistance to vibrations
  • Designed to avoid surface damage while tightening

Bogie Hex Head Locking Screws

Our bogie hex head locking screws feature a cross-functional design with a serrated flange. Key attributes include:

  • Will not unscrew or become loose
  • A serrated, cross-functional washer that is integrated into the flange
  • Prevents the likelihood of forgetting safety washers
  • Prevents the possibility of using the wrong orientation

Bogie Wedge Locking Washers

Bossard’s bogie wedge locking washers have a unique self-locking design through tension. Features include:

  • High retention of the clamp load
  • Easy and quick dismantling and installation
  • High resistance to corrosion
  • Excellent resistance to vibration
  • Maximized safety against loosening

Bogie Tension Control Bolts

Our bogie tension control bolts ensure the cost-efficient installation of high-strength pre-loaded bolts. These key fasteners offer:

  • A safe tightening process because of a high-level clamp load
  • Innovative anti-corrosion protection that is designed to accept paint
  • Delivers consistent tension even in a high-vibration environment

Connecting the Railway Industry to Better Solution

At Bossard, our engineers specialize in advising clients on the best fastening solution, specific material requisitions, and innovative developments. In the event the most ideal solution doesn’t exist, we will work closely with you to develop one that best meets your needs.

Contact Bossard today at ProvenProductivity@bossard.com.

 

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Types of Fastener Hardness Testing

Types of Hardness Testing

Hardness defines how a material resists permanent deformations such as indentation. Because measuring this characteristic is a mature technology, several hardness methods are available that produce different hardness values.

Parts like fasteners are typically tested at heat treatment to affect the process and the outcome. However, these tests are also conducted on raw materials for high-strength fasteners or some coating finishes.

Advantages of Hardness Testing

Such tests are quick and easy, relatively inexpensive, and can work on finished components since they do not destroy the specimen, which can be of any size and shape, such as a fastener. In general, mechanical hardness tests rely on an indenter made of tough material, such as hardened steel, carbide, or diamond. It presses into the surface of the test component at a specific force.

The hardness values come from either how deeply the indenter penetrates or the size of the indent with smaller indents signifying harder materials. Higher numbers mean harder materials.

Types of Tests

The following are just three of the major hardness tests. Tables are available for converting one hardness test scale to another. However, some of these values are interpolated because there is no direct mathematical correlation among scales. You should only use conversion tables as a last resort.

Brinell Hardness Test

In the early 20th century, the Brinell Ball Test stood out as the most popular. It presses a hard ball into the test material with a known load. Based on EN ISO 6506-1 standards, a typical value from this test is 600 HBW 1/30/15, which means:

  • 600 – Brinell hardness number
  • HB – Hardness symbol for Brinell
  • W – Indenter type, which is tungsten carbide
  • 1 – Diameter of the ball in millimeters.
  • 30 – kilogram-force (applied force)
  • 15 – Duration of the test force in seconds

Rockwell Hardness Test

The Rockwell Hardness Test starts with a light load and then continues with a heavier load at a specific duration with an indenter. The heavier load is removed, leaving only the indent by the light load. The difference in depth between the two loads represents the Rockwell hardness number. A typical value from this test is 60HRBW, which means:

  • 60 – Rockwell hardness value
  • HR – Hardness symbol for Rockwell
  • B – Rockwell scale symbol
  • W – Ball type, which is S for steel and W for tungsten

Vickers Hardness Test

This test uses a square-based pyramid indenter. (A variant of this test, Micro Vickers testing is reserved for a small or limited area. An example is the carburized surface of a gear for testing the surface, core, and carburized thickness.)

The test impresses as a reference for deciding a dispute between hardness results. A typical value from this test is 640HV30/10, which means:

  • 640 – Vickers hardness value
  • HV – Hardness symbol for Vickers
  • 30 – Kilogram force (applied force)
  • 10 – Duration in seconds

Contact Us

Do you want more information on hardness testing methods or how it can affect your choice of fasteners? Then please contact us today at ProvenProductivity@bossard.com.

 

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Find Coefficient of Friction (And more!) with Fastener Testing from Bossard

#3 Fastener Testing - r

Whether your products are used in systems that are common or critical, you want to ensure that they meet the high standards of your target market. Bossard can help with 14 state of the art testing labs on three continents that boast ISO/IEC 17025 certification. Our services reward you with high quality at minimal risk.

Our facilities can take charge of the following wide range of fastener tests on your products.

  • Tensile Testing and Compression Strength Testing is a standard procedure that can determine yield point, tensile strength, elongation fracture, and other mechanical characteristics.
  • Hardness Tests / Hardness Profile Measurements rely primarily on measure indentations to test mechanical properties such as case hardness, hardness profile, surface hardness, and core hardness.
  • Friction Coefficient Testing / Torsion Testing can find the coefficient of friction to determine the clamping force and tightening torque. We recommend this test to ensure that screws are tightened in the correct order.
  • Whether at our laboratories or at your location, Torque Analysis uses your original working pieces, which are made of plastic and metals, to determine the tightening torque of your application.
  • Coating Thickness Measurement measures the thickness of the required protective coating by using X-rays and a coating thickness gauge.
  • Spectral Analysis identifies materials and ensures quality control of semi-finished and finished products.
  • Fastening Optimization helps you to choose the right fastener for your application to minimize costs in the supply chain and during production and assembly. We can also deliver the optimum specifications for your fastener.
  • Loosening Analysis examines the bolted joint to determine the right clamping force when subject to different vibrations, forces to transmit, and temperatures of use. It can determine the best way to secure the joint based on the fastener and its function.
  • Corrosion Analysis looks at how corrosion can affect fasteners and other components. We help you choose reliable countermeasures for reducing or removing corrosion from the wide array of corrosion protection systems.
  • Salt Spray Test is a standardized test for evaluating corrosion protection. It determines how different anti-corrosion coatings react on test pieces that are sprayed with a saline solution in the test chamber.
  • Ultra-Sonic Preload Measuring looks at the preloads that are generated when a screw is tightened. Because measuring the preload/clamping force is not easy, we use a special ultra-sonic measuring device that can evaluate how a change in screw length affects preload.
  • Failure Analysis determines the root cause of failures and the best ways to prevent them. Among possible reasons are change of friction conditions, too much or too little tightening, loss of preload due to setting, and corrosion.,
  • Joint Design Calculation, which is based on the MDESIGN tool, enables us to recommend the best design and assembly based on calculations of contact surface pressure, variation of friction, assembly method, and different expansion coefficients of fasteners and other components.

To find out more about how any of our tests can help make quality assurance more reliable and improve the design and assembly of your products, please contact us today at ProvenProductivity@bossard.com.

 

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Fasteners for Electric Vehicle Body in White Design

Fasteners for Electric Vehicle Body In White Design

When you’re looking for the right fasteners to use with electrical vehicles, trust Bossard to deliver smart solutions. We understand that your customers are focused on social responsibility, environmental concerns, and sustainable CO2 balance. We can help you choose the fasteners that make your products competitive now and in the future.

Why Bossard?

Relying on our expertise rewards you with several advantages:

We act as your one-stop shop with over a million fastening solutions, control elements, and electric assembly accessories. If you’re looking for a specific fastener for EV development, you’ll find it at Bossard.

Our many years of market experience in the EV sector has produced many successful projects and long-standing relationships with innovative partners.

The quality of our suppliers is backed by test laboratories with ISO-IEC 17025 certification in 10 countries around the world.

One size does not fit all with us. We tailor our solutions to your individual requirements.

Through Smart Factory Logistics, you can focus on your core expertise while we fully automate the logistics behind B- and C-part management and make them more transparent.

When you need assistance in developing products, you can consult our Expert Design service to help you choose the right fasteners and materials from the beginning. We can also assist with prototypes and small series.

Body in White Fasteners

Body in White (BIW), which is the main frame of the vehicle that has been joined together using different types of joining processes. The attachment to this structure has many different demands and will usually require high-strength fasteners that are corrosion resistant and are easy to assemble and disassemble. To meet those requirements, we offer the following types of fasteners:

Weld Nuts & Studs

Through welding, metal fasteners such as weld studs, weld pins, and threaded studs and weld nuts are joined to another metal object through an arc at the speed of lightning. The process can be highly automated and depending on the type of welding it can only requires access to one side of the material.

PEM® Large Diameter Clinching

Hardened clinch fasteners increase thread strength and produce clean assemblies. The fasteners can either be installed In-DIE during the forming process or offline using a C-Frame. There are no thermal stresses even with the high resistance to push and torque outs. The resulting clean work environment reduces any concerns about the environment.

Self-Piercing Technology, Flow Drill Screws

These fasteners combine drilling and thread forming to increase the speed of one-sided assembly, which drops to less than one minute. Because the rivets are self-piercing, the material experiences no heat zones during installation. The flow drill screws are highly resistant to vibration and loosening torque.

Structural Blind Rivets

Because they stand out as a strong solution for structural assembly, these fasteners are excellent for high-tensile applications. Only one side is needed for access and one fastener can accommodate up to four rivets with large diameters. The result is an attachment that is both durable and reliable.

Next Steps

If you have any questions or want to get started with our solutions, please contact us today at ProvenProductivity@bossard.com.

 

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A Quick Guide to the Types of Rivets

Rivet Technology

Welcome to the expansive world of rivets. A rivet is a highly effective mechanical fastener comprised of a cylindrical stem on one end and the head on the other. As leaders in fastening technology, Bossard offers years of experience and knowledge designed to help you confidently make the best fastening decision for your application. Let’s take a closer look at three main types of rivets:

  • Blind Rivets
  • Blind Rivet Nuts
  • Lock Bolts

Blind Rivets

Also known as break stem rivets, blind rivets are simply tubular fasteners with a mandrel in the middle. To apply blind rivets, they must be inserted into pre-drilled holes in the parts that are to be joined with a special tool that draws the mandrel through the rivet’s body. Then the blind end will expand, and the mandrel will be snapped off.

One of the most desirable attributes of blind rivets is they only require a one-sided exit. This is a massive benefit because most fastening solutions will require a two-sided exit. There are several different types of blind rivets, including:

  1. Non-structural: Engineered for applications with medium requirements regarding tensile and shear force.
  2. Structural: Employed by applications that have a higher requirement regarding tensile and shear force.
  3. Speed: Used in applications where manufacturing speed is paramount. These types of rivets are suitable for applications with low requirements for tensile and shear force. 

Applications for Non-Structural Rivets vs Structural Rivets

The difference between these two types is the breaking point of the mandrel. On structural rivets, the breaking point is predefined and breaks always above the sheer edge of the application material. Also, the mandrel is mechanically locked inside the blind rivet body, which means it never falls out. The design of a structural rivet ensures the mandrel always supports the mechanical force/resistance in terms of shear and tensile forces regarding the fastening point. 

A Closer Look at Speed Rivets

As the name suggests, speed rivets are used where manufacturing speed is necessary, and there are no high requirements for tensile and shear force within the application. The biggest advantage of utilizing speed rivets against other types of blind rivets is you don’t have to reload the installation gun each time you want to install it. 

Blind Rivet Nuts

Blind rivet nuts are multifunctional fasteners. At first, blind rivet nuts can perform like a blind rivet — fastening two or more materials together with only a one-sided exit. However, the key advantage of using blind rivet nuts is their versatility in working with a vast range of materials.

Specifically, they can be used to bring in a strong and reliable thread into a thin or thick sheet metal plate, profile, composite, or plastics where thread forming is impossible. There are many types on the market. 

  • Standard rivet nuts with an open-end
  • Standard blind rivet nuts

Lock Bolts

As a high-strength fastening solution, lock bolts consist of a separate pin and collar that are mechanically locked during the installation process. These fasteners boast the ability to withstand the toughest applications and environments that traditional screw and rivet joints wouldn’t be able to perform. Lock bolts also offer excellent resistance to vibration and material fatigue. 

Ready to learn more about choosing the best rivet for your application? Watch our latest video — Rivet Technology from Bossard — and then reach out to the Bossard team for tailored fastening solutions. 

 

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Open the Door to the World of Access Solutions with Bossard

Open the Door to the World of Access Solutions with Bossard

No matter your industry or segment, protecting what needs to be protected is critical. And when it comes to different access locking and control solutions, the team at Bossard can and will help. Our seasoned team of access locking and control engineers specialize in helping other engineers and product developers create more secure and reliable solutions.

Let’s take a quick look at a few key types of access locking and control solutions. To see these mechanisms in action in everyday scenarios, watch our latest video: Access Solutions from Bossard

 

What Is a Cam Latch?

The cam latch is a relatively simple locking mechanism designed to secure access to entry points and panels. Cam latches are made up of a latch and body that rotates when actuated to release or secure.

What Are Draw Latches and Hinges? 

Draw latches function by leveraging the simple principle of drawing two parts or items together by using tension. The key parts of a draw latch assembly are:

 

  • The blade, which can be a wire-formed loop, hooked plate, or another mechanism. 
  • The keeper, which is a hooked plate engineered to receive the blade. 
  • The hinge, which is discussed in more detail below. 


With a draw latch, the tension is established when the blade is connected to the keeper and then clamped down. For most draw latches, the tension is released as the latch is rotated into a vertical position; while the horizontal position usually results in tension being applied. 

What Is a Friction Hinge?

The friction hinge — also called a torque hinge — is an important access locking and control solution designed to provide resistance to the pivoting motion of the hinge. These mechanisms are used for holding doors, lids, panels, and display devices at certain angles for long periods. 

What Is a Gas Spring?

Also called the pressure gas spring, gas pressure damper, and gas damper, gas springs are designed to solve simple to complex requirements for closing, opening, tilting, and damping tables, flaps, loungers, or seats. Unlike other mechanical springs that use elastic deformation, gas springs rely on compressed gas located inside an enclosed cylinder that is sealed with a sliding piston that pneumatically stores potential energy. At the same time, this design enables the gas spring to withstand external forces applied parallel to the direction of the piston shaft. 

Contact Bossard for Customized Access Solutions

At Bossard, we are your experienced manufacturing partner. We are home to a vast range of tailored access solutions designed for an array of applications. Don’t hesitate to reach out to us today for solutions or guidance at ProvenProductivity@bossard.com. And feel free to watch our latest YouTube video — Access Solutions from Bossard — to see many of our actual access and locking solutions in everyday scenarios. 

 

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What Is A Thread Rolling Screw?

What Is A Thread Rolling Screw

A thread rolling screw (TRS) is a type of threaded fastener that utilizes threads to reliably and securely fasten different materials. These types of screws create threads in the material by forcing the material outward. As a result, they are most popular in applications where you want to avoid loose chips that are typically created by thread-cutting screws.

What Are They?

Unlike traditional screws, thread rolling screws do not require a pre-tapped hole. As a member of the tapping screw family, these fasteners “roll” or form their own threads by displacing the material instead of removing it. The name “thread rolling screw” is typically reserved for self-tapping screws that have a coarse pitch and a standard machine screw thread form.

What’s the Difference Between a Standard Bolt and a Thread Rolling Screw?

While a standard bolt and thread rolling screw can appear to be similar, there are distinct differences. 

Standard M10 Metric Flange Screw

Flange Screw

Pictured above is a standard M10 metric flange screw. This type of screw can be threaded into a tapped hole or a mating nut. With this type of screw, make sure to recognize how the lead thread is rounded and uniform. 

Thread Rolling Screw

Thread Rolling Screw

The screws pictured above are both thread rolling screws and will create their own threads into the properly prepared light metal or steel. With thread rolling screws, it’s important to recognize the triangular shape to the point. You should also notice the distinct tapering of the first two to three threads.

The unique tapered lead threads and different shapes are instrumental in helping start rolling threads in the mating material. Although several different point styles can be used with thread rolling screws, they must all meet performance specifications in the corresponding fastener standards such as: 

Key Characteristics of Thread Rolling Screws

Thread rolling screws are typically case-hardened. This attribute allows them to create threads into ductile metals that may be up to twice their diameter. The surface hardness of the screw must be harder than the material it’s being threaded into. And thread rolling screws are not ideal for brittle materials, such as cast iron. 

Understanding the Fastener Hole

When using thread-forming fasteners, hole preparation is paramount. The hole size can vary based on the thickness and type of material. Because of this, it’s vital to refer to foundational literature, such as the chart below: 

Strength Characteristics

You can view this table and other technical literature on the technical section of our website at www.bossard.com.

When creating a pilot hole, the displacement of the material at the entrance of the hole must be taken into consideration. One tip is to add a countersink to the hole, so the bulge isn’t created upon thread forming. The creation of a bulge could result in the parts not seating flat against each other.  

Contact Bossard for Thread Rolling Screws

When deciding whether to use thread-rolling screws, it’s important to evaluate the needs of your application. And the engineers at Bossard offer decades of experience providing expert guidance in all matters involving fasteners and thread rolling screws. 

For more information on Thread Rolling Screws or any type of fasteners, check out www.bossard.com or contact us at ProvenProductivity@bossard.com.

 

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Valley Forge and Bolt Introduces High-Temperature Maxbolt

Bossard carries many products, such as bolts and screws, that work well for conventional applications, including industrial automation, automotive, rail, and robotics. However, applications exposed to high temperatures demand fasteners for high-temperature applications with greater mechanical and physical durability. To meet those more stringent requirements, we are proud to introduce High-Temperature Maxbolt™ from Valley Forge & Bolt.

Building on the Original

If the name sounds familiar, it’s because you may have already used the original Maxbolt Load Indicating Fastener System. This innovation introduced an accurate and durable analog gauge into the head of the bolt. The gauge monitors the load to minimize the potential premature wear and catastrophic joint failure that leads to expensive downtime.

The Maxbolt analog gauge contains a custom scale that shows the normal operating range of the bolt using either precise clamp load values or a green zone.

  • Technicians only have to glance at the gauge to discover when the proper load is reached.
  • During normal operations and in real-time, they can determine if the bolt is loosening or falling out of spec. They can then take steps to address the issue immediately instead of waiting for equipment to fail.

The entire system does away with torque charts and tightening patterns as well as dispenses with expensive strain gauges, ultrasonic machines, and torque-measuring devices.

Maxbolt fasteners do not require special tools. They work with conventional tightening and tensioning equipment. These advantages ultimately improve safety and increase savings by reducing maintenance.

The high-temperature fasteners are available in standard shapes and sizes, so they can be retrofitted into existing assemblies. To ensure that each fastener meets the tension requirements of your application, it is calibrated and tested to its proof load.

Working with High Temperatures

Because the load-monitoring gauge is sealed, the original Maxbolt tolerates submersion and harsh environments in temperatures ranging from -40 °F to 180 °F. In contrast, the High-Temperature Maxbolt withstands temperatures up to 650 degrees Fahrenheit.

Like the original, this latest version boasts an accuracy of +/-5%, is compliant with ASTM F2482, and operates under rapid thermal cycles or in prolonged high temperatures. The High-Temperature Maxbolt is also available in the standard diameters and grades of the original. It’s designed for such industries as metal and mineral refining, energy generation, metal forming, furnace manufacturing, and chemical processing.

“We know customers have been eager for a high-temperature version of Maxbolt® because they value the safety and time-savings it brings to their applications,” says James Brooks, head of engineering and business development for Valley Forge & Bolt. “We’re pleased that we have combined the right blend of materials and precision worthy of the Maxbolt® name.”

For more information about the Valley Forge and Bolt High-Temperature Maxbolt, reach out to us at ProvenProductivity@bossard.com.

 

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Case Study: Thread Forming Screws for Space Constrained Application

Thread Forming Screws

Small Changes Sometimes Upset Industrial Processes

Thermoplastic materials can produce a wide array of products that get used in industrial processes, including auto manufacturing. When an automaker wants to make a design change to an existing injection molding tool, there may be costly consequences.

This was exactly the case when an automotive client came to us a few months ago with a thread-forming fastener request for their PC+ABS thermoplastic assembly.

Not Enough Space for the Ideal Type of Screw

Since they had already made the tooling for their injection molding process, they wanted us to try and fit a screw into their existing design. The existing hole diameter was 5mm with space for an 8mm long screw. However, the recommended thread engagement length for this type of screw in thermoplastic materials was 10mm, or roughly twice the diameter. In addition, they had space constraints around the head of the screw. They needed us to find a solution and supply fasteners quickly for a rapid ramp-up.

Simulation Technology Reveals a Solution

To resolve the space constraint issues around the head of the screw, we considered using flat head screws. However, our simulation technology showed that switching to a Torx head screw with a round washer head was the only option suitable to achieve the performance requirements for their soft thermoplastic material.

Production Starts with Proper Parts in Place

Ultimately the customer did have to make minor changes to the existing boss, but once the design was finalized, we located inventory of the thread forming Torx screws quickly for prototypes and testing. Today we are supplying parts for production.

For more information about automotive fastener needs in thermoplastic materials, email us at ProvenProductivity@bossard.com to speak with a Bossard engineer.

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