Infastech Insert Design Guide

Infastech
Offices

www.infastech.com
 The relationship between the plastic and inserts The characteristics of Knurl and inserts
infastech brass inserts

• Crystalline plastics is relatively insensitive to stress, can apply for a variety of inserts.
• Non-crystalline plastic is very sensitive to stress, the choice of inserts models should
avoid sharp Knurl. For plastics who need to shield plating should be particularly careful,
the plastics buried inserts can cause serious cracking issue after acid washing process. Helix angle

It is best to plating first, then buried inserts. Knurl

• Thermoset plastics does not apply for hot melt and ultrasonic burying, if it’s necessary,
you can choose sophisticated and sharp Knurling with compression inserts process. Groove
Pitch
Lead

Plastic characteristics
Thermoset Plastics Thermoplastic Plastics
Will not soften by heating Will soften by heating
High hardness and easy broken Good flexibility
Good surface hardness Can be recycled
More stable with microstructure Easy for injection molding process Twist-pull relationship with the helix angle
Good heat resistance performance
Difficulty for injection molding process Helix angle vs strength

Pull force

KN (KN.M)
Crystalline plastic

Torque

30 35 40 45 50 55 60
Helix angle
Non-Crystalline plastic
Groove and Oriented Inserts materials and surface treatment
• Standard Brass C3604
• Low-lead copper in line with the EC ROHS environmental protection requirements
• Stainless steel / tin, free cutting iron
• Surface Treatment: Under normal circumstances, inserts is not necessary for the
Lead particular surface treatment. If a special request, the plating can be used for processing.

• The effect-oriented role of lead can Groove can accommodate the plastic
enhance the efficiency, at the same to improve the pull force
time to avoid the deflection and boss
hole crack
• Make sure the size of D is larger than
d 0.03mm at least.

Brass Insert Applications Inner Thread Specification

Herringbone For thermoplastic plastics application with ultrasonic and Nominal Size Toleranc e Aiguille dia Hole dia, GO Hole dia, NO-GO
hot-melt install process. Herringbone knurl can improve pull-out performance m.m. Inch m.m. Inch m.m. Inch
M1X0.25 5H 0.77 0.0303 0.75 0.0295 0.785 0.0309
Shoulder For bigger draft angel (8 degree) plastic boss hole application. M1.2X0.25 5H 0.97 0.0382 0.95 0.0374 0.985 0.0388
M1.6X0.35 6H 1.3 0.0512 1.25 0.0492 1.321 0.052
Groove with taper I For bigger draft angel plastic boss hole application.
Diagonal knurl & taper can increase 25% torque & pull out performance M1.7X0.35 6H 1.39 0.0547 1.35 0.0531 1.421 0.0559
M2X0.4 6H 1.64 0.0646 1.61 0.0634 1.679 0.0661
Groove with taper II For bigger tolerance plastic boss hole application and M2.5X0.45 6H 2.12 0.0835 2.058 0.081 2.138 0.0842
provide good performance
M2.6X0.45 6H 2.23 0.0878 2.184 0.086 2.26 0.089
Symmetry I Fit with Auto install line. And herringbone knurl offer great torque M3X0.5 6H 2.58 0.1016 2.515 0.099 2.599 0.1023
& pull out performance M3.5X0.6 6H 2.97 0.1169 2.926 0.1152 3.01 0.1185
M4X0.7 6H 3.38 0.1331 3.34 0.1315 3.422 0.1347
Symmetry II For small plastic products with thin boss hole wall thickness
M5X0.8 6H 4.29 0.1689 4.2 0.1654 4.334 0.1706
Symmetry III For non-crystalline plastic application. Round knurl can avoid M6X1.0 6H 5.08 0.2 5 0.1969 5.153 0.2029
sharp teeth. M7X1.0 6H 6.09 0.2398 6 0.2362 6.153 0.2422

Rivet For thin plastic plate application M8X1.25 6H 6.83 0.2689 6.75 0.2657 6.912 0.2721
M10X1.5 6H 8.61 0.339 8.5 0.3346 8.676 0.3416
Direct Push-in For most of thermoplastic plastics application and needn’t M12X1.75 6H 10.38 0.4087 10.25 0.4035 10.44 0.4111
special equipment

Full Burial For most of thermoset plastic application with sharp knurl.

Outer thread One kind of self-taping insert, use for both thermoset &
thermoplastic application.
Outer Thread Specification I Direct Push-In Type

Internal Thread Size L Insert T Head H Head W Insert Rec.Hole Rec.Hole Min.Wall Internal Thread Size L Insert T Head H Head W Insert N Pilot End No of Fine Rec.Hole Min. Wall
Inch ISO Metric Length Thickness Diameter Diameter Size Size Thickness Inch ISO Metric Length Inches Thickness Diameter Diameter Diameter -0.000 Thickness
Inches Inches Inches Inches Thermoplastics Thickness Inches Inches Inches Inches Inches +0.004 as
Inches +0.004 Inches Inches Inches

#2-56 M2x0.40 .236 .023 .236 .177 .157-.161 .161-.159 #2-56 M2x0.40 .157 .018 .189 .147 .123 2 .126 .063
#4-40 M2.5x0.45 .236 .023 .236 .177 .157-.161 .161-.159 #4-40 M2.5x0.45, M3x0.5 .226 .023 .217 .178 .154 3 .157 .079
- M3x0.5 .236 .023 .236 .197 .177-.181 .181-.189 #6-32 M3.5x0.6 .281 .029 .250 .209 .185 4 .189 .094
#6-32 M3.5x0.6 .315 .029 .295 .236 .209-.213 .217-.224 #8-32 M4x0.7 .321 .035 .281 .240 .218 5 .220 .110
#8-32 M4x0.7 .315 .035 .315 .256 .228-.232 .236-.244 Evaluate by #10-24 - .375 .042 .312 .274 .248 5 .252 .126
#10-24 - .394 .042 .374 .315 .280-.283 .287-.299 pre-production #10-32 M5x0.8 .375 .042 .312 .274 .248 5 .252 .128
#10-32 M5x0.8 .394 .042 .374 .315 .280-.283 .287-.299 tests #1/4-20 M6x1.0 .500 .052 .375 .337 .310 7 .315 .157
#1/4-20 M6x1.0 .551 .052 .472 .394 .339-.346 .354-.370 #1/4-28 - .500 .052 .375 .337 .310 7 .315 .157
#1/4-28 - .591 .052 .472 .394 .339-.346 .354-.370 #5/16-18 M8x1.25 .500 .052 .433 .400 .374 7 .378 .189
#5/16-18 M8x1.25 .591 .052 .551 .472 .417-.425 .433-.449 #5/16-24 - .500 .052 .433 .400 .374 7 .378 .189
#5/16-24 - .591 .052 .551 .472 .417-.425 .433-.449
#3/8-16 M10X1.5 .709 .062 .630 .551 .496-.504 .512-.528
#3/8-24 - .709 .062 .630 .551 .496-.504 .512-.528

Shoulder Type

Outer Thread Specification II

Internal Thread Size L Insert T Head H Head W Insert N Pilot End Rec.Hole Min.Wall
Inch ISO Metric Length Inches Thickness Diameter Diameter Diameter -0.000 +0.004 Thickness
Inches Inches Inches Inches Inches Inches

Internal Inch Thread Size ISO Metric L Insert Length Inches W Insert Diameter Rec.Hole Min.Wall Thickness #2-56 M2x0.40 .157 .021 .187 .141 .123 .126 .051
Inches -0.0000 +0.004
Inches #4-40 M2.5x0.45, M3x0.5 .226 .024 .218 .181 .154 .157 .063
#6-32 M3.5x0.6 .281 .030 .250 .214 .185 .189 .071
#2-56 M20x0.40 .157 .146 .126 .063
#8-32 M4x0.7 .321 .036 .281 .248 .218 .220 .083
#4-40 M2.5x0.45,M3x0.50 .228 .177 .157 .079
#10-24 - .375 .043 .312 .278 .249 .252 .102
#6-32 M3.5x0.60 .283 .209 .189 .094
#10-32 M5x0.8 .375 .053 .312 .278 .249 .252 .102
#8-32 M4x0.70 .323 .242 .220 .110
#1/4-20 M6x1.0 .500 .053 .375 . 341 .312 .315 .130
#10-24 - .374 .272 .252 .126
#1/4-28 - .500 .053 .375 .341 .312 .315 .130
#10-32 M5x0.80 .374 .272 .252 .126
#5/16-18 M8x1.25 .500 .053 .437 .403 .374 .378 .177
#1/4-20 M6x1.0 .500 .335 .315 .157
#5/16-24 - .500 .053 .437 .403 .374 .378 .177
#1/4-28 - .500 .335 .315 .157
#3/8-16 M10x1.50 .500 .063 .551 .494 .465 .469 .236
#5/16-18 M8x1.25 .500 .398 .378 .189
#3/8-24 - .500 .063 .551 .494 .465 .469 .236
#5/16-24 - .500 .398 .378 .189
Single Groove with Taper Symmetry Type

Thread Size Thread Size Overall Insert Pilot Recommended Hole Size Minimum Wall
Inch Metric Length Diameter Diameter d +/_.001 Thickness Internal Thread Size L Insert T Head H Head W Insert N Pilot End Rec.Hole Min.Wall
L W N +/_.001 D S Inch ISO Metric Length Inches Thickness Diameter Diameter Diameter -0.000 +0.004 Thickness
Inches Inches Inches Inches Inches Inches
#2-56 M2x0.40 .115 .136 .115 .123 .118 .080
#4-40 M2.5x0.45 .135 .172 .157 .159 .153 .093 #2-56 M2x0.40 .155 .020 .187 .137 .123 .126 .055

#6-32 M3x0.50 .150 .220 .203 .206 .199 .116 #4-40 M2.5x0.45,M3x0.5 .228 .023 .217 .174 .154 .157 .071

- M3.5x0.6 .150 .220 .203 .206 .199 .116 #6-32 M3.5x0.6 .281 .029 .250 .206 .185 .189 .083

#8-32 M4x0.7 .185 .250 .230 .234 .226 .133 #8-32 M4x0.7 .320 .035 .280 .239 .218 .220 .094

#10-24 - .225 .296 .272 .277 .267 .159 #10-24 - .374 .042 .312 .270 .249 .252 .110

#10-32 - .225 .296 .272 .277 .267 .159 #10-32 M5x0.8 .374 .042 .312 .270 .249 .252 .110

- M5x0.8 .265 .328 .308 .315 .303 .171 #1/4-20 M6x1.0 .500 .052 .375 .333 .312 .315 .142

#1/4-20 M6x1.0 .300 .375 .354 .363 .349 .194 #1/4-28 - .500 .052 .375 .333 .312 .315 .142

#1/4-28 - .300 .375 .354 .363 .349 .194 #5/16-18 M8x1.25 .500 .052 .437 .393 .375 .378 .197

#5/16-18 M8x1.25 .335 .469 .439 .448 .431 .245 #5/16-24 - .500 .052 .437 .393 .375 .378 .197

#5/16.24 .335 .469 .439 .448 .431 .245

#3/8-16 M10x1.50 .375 .563 .530 .540 .523 .293
#3/8-24 - .375 .563 .530 .540 .523 .293
Full Burial Type

Twins Groove with Taper

Internal Thread Size L Insert T Head H Head W Insert N Pilot End Rec.Hole Min.Wall
Inch ISO Metric Length Inches Thickness Diameter Diameter Diameter -0.000 +0.004 Thickness
Thread Size Thread Size Overall Insert Pilot Recommended Hole Size Minimum Wall Inches Inches Inches Inches Inches Inches
Inch Metric Length Diameter Diameter d +/_.001 Thickness
L W N +/_.001 D S #2-56 M2x0.40 .162 .020 .187 .131 .117 .122 .063

#2-56 M2x0.40 .188 .136 .115 .123 .107 .080 #4-40 M2.5x0.45,M3x0.50 .208 .023 .217 .165 .146 .150 .079

#4-40 M2.5x0.45 .219 .172 .144 .159 .141 .093 #6-32 M3.5x0.60 .247 .029 .250 .196 .178 .181 .098

#6-32 M3x0.5 .250 .220 .190 .206 .185 .116 #8-32 M4x0.7 .292 .035 .281 .228 .209 .213 .098

- M3.5x6 .250 .220 .212 .206 .185 .116 #10-24 - .326 .042 .312 .259 .241 .244 .098

#8-32 M4x0.7 .312 .250 .251 .234 .208 .133 #10-32 M5x0.8 .326 .042 .312 .259 .241 .244 .098

#10-24 - .375 .296 .251 .277 .246 .159 #1/4-20 M6x1.0 .362 .052 .375 .322 .304 .307 .110

#10-32 - .375 .296 .283 .377 .246 .159 #1/4-28 - .362 .052 .375 .322 .304 .307 .110

- M5x.8 .438 .328 .332 .315 .278 .171 #5/16-18 M8x1.25 .362 .052 .437 .383 .365 .366 .150

#1/4-20 M6x1.0 .500 .375 .332 .363 .321 .194 #5/16-24 - .362 .052 .437 .383 .365 .366 .150

#1/4.28 - .500 .375 .406 .363 .321 .194 #3/8-16 M10x1.50 .362 .062 .551 .499 .481 .484 .197

#5/16-18 M8x1.25 .562 .469 .406 .448 .401 .245 #3/8-24 - .362 .062 .551 .499 .481 .484 .197

#5/16-24 - .562 .469 .439 .448 .401 .245

#3/8-16 M10x1.50 .625 .563 .493 .540 0.488 .293
#3/8-24 - .625 .563 .493 .540 0.488 .293
Slotted Type Plastic Hole Size and Wall Thickness

Internal Thread Size L Insert T Head H Head W Insert Recommended Minimum Wall
Inch ISO Metric Length Inches Thickness Diameter Diameter -0.000 +0.004 Thickness Inches L1= insert length
Inches Inches Inches Inches L2= min. hole depth
W= wall thickness
#2-56 M2x0.4 .155 .017 .187 .124 .126 .094
T= draft angle
#4-40 M2.5x0.45,M3x0.5 .186 .020 .218 .156 .157 .126
#6-32 M3.5x0.6 .249 .026 .250 .186 .189 .142
#8-32 M4x0.7 .312 .032 .281 .217 .220 .157
#10-24 - .371 .039 .312 .249 252 .189
Plastic Hole - Taper
#10-32 M5x0.8 .371 .039 .312 249 .252 .189
#1/4-20 M6x1.0 .497 .049 .375 .311 .315 .236
#1/4-28 - .497 .049 .375 .311 .315 .236
#5/16-18 M8x1.25 .497 .049 .437 .374 .378 .276 L1= insert length
L2= min. hole depth
#5/16-24 - .497 .049 .437 .3744 .378 .276
W= wall thickness
T= draft angle

Production Process Plastic Hole Contour

Production Process

Design Engineering QA Final Inspection

Note: Under normal circumstances,
Tool Fabrication Move to Package Area inserts has oriented segment , do
not need bevel on the plastics

Raw Material Packing

Permanent Weld Removable Assembly
Cutting Shipping
Permanent Weld Removable assembly
Washing Part Final Audit Plastic Hole Depth
• Adhesive connection • Self-drive screw clip
• Welding • Plastic thread
Drying - Ultrasonic Welding • Metal Insert
- Friction welding - Forming mold
- Hot-melt welding - Secondary burial (thermography,
Note: Depth of plastic design, plastic overflow
ultrasound) space must be considered, under normal
circumstances is between 0.5-1.5mm
Plastic Conjugation Line Insert Outside Diameter and Plastic Hole factor

Outside Diameter (Body)

• Fit into the hole
• Length (Body)
Note: the location of the plastic boss • Fit into the hole depth
hole should be advised not to set
up onconjugation line, to avoid the Knurling length (Performance Consideration)
breakdown of the plastic hole with stress • Knurl
• Pitch
• Number of knurl division

Thread
• Thread standard
Inserts Application • Chips

• The relationship between outline of the inserts and boss hole

• The relationship between size of the inserts and boss hole Brass Insert Installation
• Installation method of insert
• Application information of insert • Ultrasonic Installation
• Performance test of insert • Thermal/Heat Installation
• Design of Blind hole • Mold-In Installation
• Quality of inserts • Press-In Installation

Insert Figure and Plastic Hole Factor Ultrasonice Installation

Installation Principle: Ultrasonic installation uses electrical energy to create high frequency vibration. The
Pilot lead-in:
vibration creates friction and thus melts the plastic material around the insert. The insert is forced into the
• Tapered Hole (8 degrees): With ribs lead in hole
plastic and the plastic flows around the insert body. Once the plastic material cools the insert is locked in-place.
• Straight Hole: With a Flat head lead in hole

Notes: Ultrasound can release energy instantaneously during installation, the great impact is easy to damage the
Knurls provide:
insert during the process, specially on thread area. Suggest to not use the process for M1.6 or smaller brass insert
• The performance function (torque ,tensile)
- Diamond Knurl (Raised/ Inverted)
- Diagonal Knurl ( Single knurl/ Opposing knurl) Electric Heating Installation
- Straight Knurl (Increases Torque Performance)
Principle: Heating the inserts to certain temperature and then force the insert into the plastic and the plastic
Undercut: flows around the insert body. Once the plastic material cools the insert is locked inplace.
• Allows plastic to flow into grooves for higher pullout resistance

Flange:
• To eliminate direct contact of plastic with mating parts
• Increases push in performance
Molded In Installation Method Plastic Material

Principle: • Thermoplastic plastics: PC/ABS ..…. Usually used in mobile phone industry. Preferred insert
• Use Molding Pin as fixture installation method: ultrasonic and hotmelt.
• Counter bore design for accurate alignment of the insert to the plastic part • Thermoset plastics: Can not be used for the installation of ultrasonic and hot-melt. Preferred insert
• Blind Insert installation method: Mold-in; Threaded in & Press-in
• Blind-end or closed-end inserts help prevent plastic ingress • Knurl
- Straight knurl: Provides maximum torque out performance
Notes: - Diamond/ Diagonal knurl: To increase the torque out and pull out resistance
• In order to improve the accuracy of the thread, all the thread tolerances should
follow with the old version of the ISO standard screw holes regulation.
• Attention to the choice of moulding point in order to avoid inserts displacement
caused by the plastic flow.
• The tolerances of pin must be strictly controlled, the specific parameters should Brass Insert Performance Testing
reference the old version of the ISO standard. (Should be less than the under
limitation about 0.01-0.03mm)
Torque

Thermal/Heat Installation Force

Pull Force
Temperature is too high
Plastic
Temperature Plastic hole spillover
wall up is scrap surface Not in place

Temperature is too low

Plastic hole Lower pull and Plastic hole

crack torsional scrap Nut scrap

Under the better burial process,

there will be plastics on the surface
when pull out the inserts from the
plastic hole
 Blind Hole Design Guide
Brass Inserts Testing Contents
•General Boss Design Information
•Hole Depth = “L” +0.9mm
•Hole Diameter = “C”+0.1~0.15mm
curve of torque •Boss Outer Diameter = “C” x 2~2.5
under the assembly

Torque

Fastener Specifications
Material: Brass
Finish: Cleaning
• Turns Thread: Class 2B, per ASME B1.1, 6H ISO Metric
Installed with heat or molded in. Designed for use
in straight holes. Flange provides a large loading
surface

Pull Torque force Indirect torque Indirect tensile

Installation Type Plastic Family Pre-Molded Performance

Thermo-Plastic Thermoset Hole
Ultrasonic • • Normal
Thermal/Heat • • Normal
Mold-In • Good
Threaded-In • • Bad
Press-In • • Bad