Optimizing the Use of Fasteners in Sheet Metal Fabrication

Fasteners into Sheet Metal Parts

Designing sheet metal parts with fasteners requires careful planning to streamline assembly and reduce costs. Discover how to effectively incorporate fasteners in sheet metal while avoiding common design pitfalls.

The Role of Material-Fastener Compatibility

Fasteners are secured to sheet metal by the material flowing around the fastener during installation. Therefore, material hardness plays a critical role:

  • Steel sheets: Compatible with hardened steel fasteners.
  • Stainless steel: Requires hardened stainless hardware.
  • Aluminum: Can use steel, stainless, or aluminum fasteners. Avoid galvanic corrosion by opting for stainless or aluminum fasteners, as steel and aluminum contact causes rapid corrosion in humid environments.

Tips for Aluminum Sheets

Although aluminum accepts various hardware types, consider:

  • Corrosion risks: Avoid steel fasteners due to galvanic corrosion.
  • Coating compatibility: Stainless steel is a safer option as it resists corrosion and works with chromating.
    Plan ahead to save time and iterations by specifying stainless or aluminum hardware for aluminum parts.

Hardware Installation Challenges

Proper fastener placement is essential to avoid issues during manufacturing. Consider these factors:

Proximity to Edges and Features

Material must flow into the fastener to secure it. Maintain minimum distances:

  • Avoid placing hardware too close to edges, holes, or cutouts.
  • Near bends, ensure space for forming tools (typically ≥ 0.5 in. or 12.7 mm).

Avoid Tack Welding

Clinch fasteners are not designed to withstand the heat of welding. Use weld nuts and studs if welding is necessary, as clinch fasteners will fail under extreme heat.

Managing Stainless Steel Fastener Limitations

Hardened stainless hardware availability can be a challenge. Some types may not exist in hardened stainless, while others require large custom orders. For panel fasteners, consider flare-in types as a viable alternative.

Best Practices for Clinch Fastener Design

  • Design for manufacturing (DFM) principles to streamline production.
  • Send a email to confirm inventory and compatibility for your chosen fasteners.
  • Provide adequate spacing and design simplicity to avoid costly iterations.

By following these guidelines, you’ll minimize costs, reduce revisions, and achieve efficient, high-quality manufacturing outcomes.

Join Our Newsletter

Subscribe to receive our latest news in your inbox!

Share:

Industries

Company

Contact Us

Follow us

Search

Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Aluminum 6061602.68193117
Aluminum 6063732.721468.9
Aluminum 70501472.83490160
Aluminum 7075(Aerospace Grade)1502.81503159
Aluminum MIC-6652.7105N/A
Aluminum 5052602.68193117
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Copper 10165 - 908.89 - 8.9469 - 36576 - 90
Copper C11065 - 908.8969 - 36576 - 90
Copper C17280 - 858.25515 - 585275
Copper C26060 - 828.53103 - 44190
Copper C36063-1308.49124-310138
Brass CZ12190 - 1608.47360 - 500220 - 360
Brass CZ13170 - 1408.5340 - 480200 - 350
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Stainless Steel 17-73887.812752046
Stainless Steel 3012178.0320521240
Stainless Steel 3031608.0324020050
Stainless Steel 3161878.0320519340
Stainless Steel 3322008.0329419644
Stainless Steel 4163607.89622009.5
Stainless Steel 4205067.8104020011.5
Stainless Steel 440C495 - 6537.8450 - 1900204 - 2152.0 - 14
Hardness(Shore D)Density (g/cm^3)Modulus of Elasticity (GPa)Tensile Strength(MPa)Elongation at Break(%)
HDPE50 - 760.92 - 0.990.565 - 1.511 - 433 - 80
UHMW-PE54 - 1200.8 - 1.80.3 - 1.111.6 - 403.5 - 800
PVC801.16 - 1.651.82 - 7.033.45 - 73.12 - 330
ABS/Nylon Blend641.04 - 1.210.9 - 5.327 - 1003.1 - 230
Acrylic600.7 - 1.30.95 - 3.7925 - 851 - 85
Nylon 6676 - 881.02 - 2.70.6 - 2510 - 981 - 300
PTFE11 - 700.7 - 3.350.392 - 0.750.86 - 41.470 - 650
PEEK62 - 941.26 - 1.722.14 - 2411 - 1251.7 - 100
POM-H811.423.27530
POM-C791.412.86740
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Titanium(Grade 1)1204.5170 - 31010324
Titanium(Grade 2)2004.51276 - 44810320
Titanium(Grade 4)2654.51480 - 65510515
Ti-6Al-4V(Grade 5)3794.43110011410
Bronze11.6 - 4205.6 - 1469 - 80072.4 - 1380 - 70
Zinc Alloy (Zamak 5)916.720870 - 1007
Steel Alloy AISI 43403887.8597220012.1
Nickel Alloy175 - 2408.44414 - 75820716