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P R O D U C T L I F E S TA R T S H E R E

SLS Insert Study

Many prototype parts require some type of mechanical fastener. Typically a threaded insert seems the logical choice, but how to best design the part to hold an insert and how to determine the mechanical limits of the insert has been somewhat unknown. Based on the results of the tests outlined in this paper, design guidelines as well as average torque limits and pull out strengths of Heli-Coils and heat staked threaded inserts can now be easily accessed in look up tables.

Design Guidelines
The selection of the insert should be based on the function the insert needs to perform. If a part requires inserts to allow for repeated assembly of components, such as electrical enclosures and lids, a heat staked insert provides high torque limit and greatly reduces the prospect of the insert being stripped out with repeated use. The inside diameter should be undersized to the recommended hole size and the outside diameter of the boss receiving the inserts should be at a minimum 1.6X the recommended hole size of the insert; a list of the recommended hole size for each size and type of insert is provided in table 2. Additionally the boss should have a minimum of two support ribs connecting the boss to the surrounding geometry (as shown in figure 1). Heli-Coil pilot holes should be designed undersize to the recommendation to allow for accurate drilling of the hole. The minimum boss size for Heli-Coils should be a minimum of 2X the recommended hole size; as with heat staked inserts, support ribs are recommended. In applications requiring maximum torque strength, Heli-Coils are not recommended.

Heat staked inserts provide high torque limit and greatly reduce the prospect of the insert being stripped out with repeated use

Test Samples and Test Equipment

Two types of test samples were built in multiple SLS materials each designed for a specific test. These test pieces were built at 3 Solid Concepts facilities utilizing 5 SLS machines. The torque limit sample as shown in figure 2 was built with pilot holes and post drilled to the correct diameter. Installation of the inserts was done using a variable heat soldering iron with specialized tips. Torque testing was done with a Sturtevant

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Richmont model CAL 36/4 torque screwdriver.

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The pull-out strength test sample and fixture as shown in figure 3 was built with a pilot hole and post drilled to the correct diameter. Installation of the Heli-Coil inserts was

Heat staked inserts will typically outperform Heli-coils if the boss size and hole size recommendations are used
Figure 1: boss detail

Figure 2: torque test sample

done using the OEM installation tools. Pull-out strength was measured using a United SSTM-20kN tensile tester and an aluminum fixture. Data: The data represents 600 data points; 5 data points per insert size, type and material. Helicoil and heat staked inserts were installed in 5 SLS materials: Nylon 12 AF Nylon 12 GF, Nylon 12 PA, NyTek 1100 and NyTek 1200CF. Inserts sizes include 2-56, 4-40, 6-32, 8-32, 10-32 and -20; Metric inserts were not tested but are considered to be equivalent in strength for each comparable insert size. Table 1 provides

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an average of the torque limit and pull-out strength for each insert size and type. An appendix to this document contains the source data and box plots of each size/type of insert separated by SLS material.

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Conclusions
The data shows important distinctions between Heli-coil and Heat staked inserts; for each insert size and material combination the heat staked inserts have higher torque strength. In terms of pull out strength, the performance of Heli-Coils and heat staked inserts is quite similar for inserts size 8-32 and smaller; larger sized heat staked inserts tend to perform better than Heli-Coils of the same size. While Helicoils do offer the advantage of a smaller boss size relative to the insert, heat staked inserts will typically outperform Heli-coils if the boss size and hole size recommendations are used.

Figure 3: pull out test sample and fixture

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Table 1
Pull-out Strength Thread Size 2-56 4-40 6-32 8-32 10-32 1/4 - 20 Heli-Coil Inserts 112.29 lbs 265.09 lbs 281.76lbs 348.75 lbs 376.94 lbs 477.93 lbs Heat Staked Inserts 116.18 lbs 229.69 lbs 394.51 lbs 331.49 lbs 434.21 lbs 640.68 lbs Thread Size 2-56 4-40 6-32 8-32 10-32 1/4 - 20 Torque Strength Heli-Coil Inserts 4.64 in/lbs 8.55 in/lbs 11.09 in/lbs 16.18 in/lbs 21.64 in/lbs 32.36 in/lbs Heat Staked Inserts 8.5 in/lbs 14.08 in/lbs 23.38 in/lbs 30.38 in/lbs >36 in/lbs >36 in/lbs

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Data shows the average pull-out and torque strength of a type/size insert. Each average is derived from 25 data points; 5 inserts per size installed in five different SLS materials.

Table 2
Heli-Coil Thread Size 2-56 4-40 6-32 8-32 10-32 1/4 - 20 Drill 3/32" #31 #25 11/64" 13/64" 17/64" Decimal .094" .120" .150" .172" .203" .266" Thread Size 2-56 4-40 6-32 8-32 10-32 1/4 - 20 Heat stake Drill 1/8" #22 #11 #1 H T Decimal .125" .157" .191" .223" .266" .358"

Recommended drill size for Heli-Coil and heat staked inserts, 2-56 1/4 -20.

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