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Product Tutorials: Threaded Inserts

What They Are

Threaded inserts provide threads in material that is otherwise too thin or soft to support tapped threads or where disassembly may be required.

Single piece assemblies combining a nut and rivet which provide high quality, load bearing female threads in thin sheet materials, box sections and tubing. They are ideal for placing in painted/coated materials as they do not damage the surface, which avoids re-work and wastage. Once installed, they are extremely resistant to pull-out and push-out pressures.

  • Blind sided assembly
  • Purely mechanical fastening
  • Designed for rapid rate of installation
  • Designed for automation
  • Forms a permanent fixture in material
  • Multi-functional fastener
  • Suitable for a wide range of installation tools


Threaded inserts consist of 4 features:
A. Head (a.k.a. Flange)
B. Body (a.k.a. Shank)
C. Splines
D. Threads



How They Work

View an interactive demo
  1. By hand, the threaded insert is turned onto the mandrel of the tool for a couple of threads to prevent cross threading.
  2. The threaded insert is pushed axially toward the tool head activating the tool motor, which spins the mandrel into the remainder of the insert. This draws the flange of the threaded insert firmly into place against the tool nose assembly.
  3. The insert, now located on the tool mandrel, is placed in the application hole and the tool is actuated. The mandrel is pulled axially toward the rear of the tool exerting a pulling force on the threads of the insert, which collapses and sets the insert.
  4. The mandrel reaches the adjustable stop in the rear of the tool, which causes the mandrel to reverse its spin out of the threaded insert. The threaded insert is now installed.



Insert Styles

Expanding Insert
  • Single piece which breaks into two pieces during installation. The lower threaded section draws up inside the upper sleeve section, causing the sleeve to expand 360o thus swaging the insert into the hole.
  • Used in sheet metals over 0.030” thick up to and including blind holes.
  • Nutsert®, Supersert®.



Bubbling Insert
  • When set, they form a bubble on the backside of the application, trapping the material between its flange and the backside bubble.
  • Must protrude through the backside to upset and form the bubble.
  • Closed End, DK, DL, Eurosert®, Hexsert®, LF TSN®, Squaresert™, TSN®.



Design Features

Example Images Design Features Design Benefits Typical Applications
Splined Body
  • Improves torque-to-turn by up to 50% compared to plain body inserts
  • Improved electrical continuity in sheet metal fixings
  • Soft materials such as aluminium, magnesium, plastics, composites and wood
  • Earthing points in electrical assemblies
Hexagonal Body
  • Improves torque-to-turn in metallic sheets by up to 200% compared to plain body inserts
  • Automotive chassis components
    requiring high resistance to turning under vibrating loads
  • Where high bolt removal torque is required during servicing (e.g. switchgear cabinets)
  • Thermal applications prone to high expansion and contraction in parent material
Square Body
  • Improves torque-to-turn in metallic sheets by up to 350% compared to plain body inserts
  • Increased punch life compared to hexagonal geometries
  • Automotive body mountings requiring maximum turning resistance
  • Soft material constructions, particularly for plastics, composites and soft sheet metals
Large Flange
  • Provides large load bearing surface
  • Reinforces hole, preventing push through
  • Potential to use flange as a spacer
  • Can be used with underhead seal (e.g. Rimlex)
  • Load bearing applications in thin sheet and soft material applications
  • Mountings where high push-out resistance is required (e.g. adjustable foot mountings)
Low Profile
  • Near flush installation and clamp up
  • Flush fitting, thin sheet, low load bearing applications (e.g. domestic appliances and coach building)
Countersunk
  • Flush installation and secure clamp up
  • Flush fitting, thin sheet, low load bearing applications (e.g. domestic appliances and coach building)
Closed End
  • Prevents ingress of dirt and fluids
    into thread
  • Prevents ingress of water and foreign bodies into electrical circuits
  • Electrical assemblies to prevent foreign bodies being inserted through open thread
  • Load bearing sections to avoid thread exposure
  • With underhead seal (Rimlex) to prevent ingress of fluids and dirt into protected environment (e.g. fuel tank)
Reduced Tail End Diameter

  • Ease of hole entry
  • Particularly suited for automation
  • Automated feed systems
  • Rapid manual assembly
Increased Thread Strength

  • Improves the maximum torque capability by typically 100% compared to standard Hexsert®
  • No risk of thread-stripping insert, avoiding expensive and time consuming re-work
  • Potential to downsize insert and screw diameter for a given joint clamp load
  • Structural automotive fixings into closed aluminium extrusions and hydro-formed steel tubes
  • High strength threads into thin, hardened steel pressings unsuited to welding
  • Any application where routine screw removal and re-tightening without torque control is likely



Inserts

Insert Family Material Key Features
Aluminum
Steel
DK
  • Splined body improves torque-to-turn & improves electrical continuity in sheet metal fixings.
  • Low profile for near flush installation and clamp up.
  • Reduced tail diameter for ease of hole entry. Particularly suited for automation.

Aluminum
Steel
DL
  • Splined body improves torque-to-turn & improves electrical continuity in sheet metal fixings.
  • Large flange provides large load bearing surface, reinforces hole, prevents push through.
  • Reduced tail diameter for ease of hole entry. Particularly suited for automation.

Steel Eurosert®
  • Splined body improves torque-to-turn & improves electrical continuity in sheet metal fixings.
  • Large flange option provides large load bearing surface, reinforces hole, prevents push through.
  • Low profile option for near flush installation and clamp up.
  • Reduced tail diameter for ease of hole entry. Particularly suited for automation.

Steel Hexsert®
  • Hex body shape improves torque-to-turn in metallic sheets by up to 200% compared to plain body inserts.
  • Large flange option provides large load bearing surface, reinforces hole, prevents push through.
  • Low profile option for near flush installation and clamp up.
  • Reduced tail diameter for ease of hole entry. Particularly suited for automation.
  • High strength option improves the maximum torque capability by typically 100% compared to standard Hexsert®.
  • High strength option no risk of thread-stripping insert, avoiding expensive and time consuming re-work.

Steel High Strength Hexsert®
  • Exceptional torque capability.
  • High speed assembly.
  • Provides high-strength threads in thin materials starting at 0.5mm.
  • Increased thread strength.
  • If excessive torque is applied, the screw shank should fail before the insert, avoiding over-tightening problems such as thread stripping and expensive rework.
  • Installed and retrofitted with standard Avdel® handtools, as well as multi-head and auto-feed robotic systems.

Steel Nutsert®
  • Expanding body style allows installation in blind holes.
  • Low profile flange for near flush installation and clamp up.
  • Reduced rear sheet protrusion.

Steel Squaresert®
  • Square body improves torque-to-turn & punch life compared to hexagonal geometries.
  • Large flange option provides large load bearing surface reinforces hole, prevents push through.

Steel Supersert®
  • Expanding body style allows installation in blind holes.
  • Low profile flange for near flush installation and clamp up.
  • Reduced rear sheet protrusion.
  • Greater mechanical performance than Nutsert®.

Aluminum
Steel
Stainless
TSN®
  • Low profile option for near flush installation and clamp up.
  • Reduced tail diameter for ease of hole entry. Particularly suited for automation.

Steel VERSA-NUT®
  • Specially designed for use in soft materials, plastics and composites
  • Quickly installed by using simple handtools (less than 3 seconds)
  • Only require blind side access
  • Extra large blind side bearing area after placing
  • Higher pull out and torque-to-turn resistance
  • Less radial loading of holes in brittle materials
  • Less risk of cracking and de-lamination of composites
  • Up to twice the grip range of standard blind inserts
  • Enables a designer to reduce the size or number of fasteners in an assembly
  • Covers large variations of thicknesses



Insert Selection

Thread Size
Avdel® threaded inserts range from M3 to M12 thread sizes dependent upon the insert. Imperial threads are also available.

Grip Range
The threaded insert should be selected to ensure that the thicknesses of the parent material(s) falls within the grip range.

Hole Size
This is specified on the relevant technical data page for the insert. Allowance for coating the parent material should be made to avoid an undersized hole.

Torque-to-Turn
Resistance is dependent upon the body shape and increases in the series: round, splined, hexagonal and square.

Special Features
Additional features such as low profile, large flange, closed end and countersunk are available within the standard range of products.

Corrosion Resistance
The selection of the material type and coating of the threaded insert should be made on the basis of the corrosion resistance required.



Application


Truck Inner Rails


Wheelable Container


Car Door Switch


Fuel Gauge


Adjustable Foot


Protective Headgear


PCB Connector


Panel Mountings


Extruded Aluminium Profiles


MORE EXAMPLES.....

Automotive
  • Roof rack attachments
  • Courtesy light switch fixings
  • Wing mirrors
  • Gear gaiters
  • Spare wheels
Building and Construction
  • Window frames
  • Fence palings
  • Security blinds
  • Steel framed buildings
  • Lift cabins
Domestic Appliances
  • Hinges on refrigerators
  • Height adjusters
  • Trim Components to cabinets
  • Switches and controls
  • Fireplaces
Electrical/Electronics
  • Fuses, switches
  • Computer chassis
  • Adjustable feet
  • Wall attachments
  • PCB to chassis
Garden Equipment/Agriculture
  • Lawnmowers
  • Cattle crushes
  • Animal feeders
  • Tractor cabs
Heating & Ventilation
  • Compressor units
  • Ducting
  • Heat exchangers
  • Burner assemblies
  • Cabinets
Medical Equipment
  • Wheelchair seats
  • Hospital beds
  • Baths
Military Equipment
  • Radios
  • Radar systems
  • Ground support equipment
  • All terrain vehicles
Office Furniture
  • Adjustable feet
  • Castors
  • Drawer runners

Installation Tools

  • Heavy duty design for demanding production environments
  • Can be suspended or hand held
  • Quick and simple to operate
  • Cycle time less than 3 seconds
Tool Description
74200 (Hydro-Pneumatic)
Places the full range of threaded inserts

74201 (Hydro-Pneumatic)
Places a range of inserts with metric (up to 8mm) and imperial threads (up to 5/16-24). Check the tool manual for specific styles and sizes

74401 (Hydro-Pneumatic)
Places a range of inserts with metric (up to 10mm) and imperial threads (up to 3/8-24). Check the tool manual for specific styles and sizes

74405 (Hydro-Pneumatic)
Places a range of inserts with metric (up to 10mm) and imperial threads (up to 3/8-24). Check the tool manual for specific styles and sizes







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