Metal Inserts Guide – 3D Printing
Another great application in 3D printing is to insert metal inserts into 3D printing to get reusable threads and / or strong joints between 3D printed parts and other elements.
What must be considered?
-
3D printing material, in insertion processes in which we melt the plastic of the piece to insert the metallic insert by means of thermal or ultrasonic processes. These processes are limited to thermoplastic materials.Within thermosetting plastics we find amorphous (such as ABS, PC, PA or PVC) that are more sensitive to stress failure and that soften with increasing temperature and semi-crystalline plastics (such as PET, PP, PA and PEEK), these plastics do not soften with increasing temperature.
-
Insert material
-
Brass: the most usedAluminum: the lightest
-
Stainless steel: it is resistant to corrosion
-
Tensile strength of the insert, is the normal force exerted on the insert necessary to extract the insert from the piece. Longer inserts have higher tensile strength.
-
-
Torsion resistance of the insert is the resistance offered by the insert to be rotated or turned on itself when tightening a screw on it. Larger diameter inserts have greater resistance to torsion.
Insertion types
Installation with heat
We apply heat to the insert using a tin soldering iron or a heat press and exert vertical pressure to gently insert the insert into the plastic part. We must have the plastic piece prepared with a hole of diameter determined by the manufacturer of inserts. The exterior walls may have a certain taper (8º) to facilitate self-aligning.
Ultrasonic installation
We apply heat to the insert using ultrasound equipment and exert vertical pressure to gently insert the insert into the plastic part. We must have the plastic piece prepared with a hole of diameter determined by the manufacturer of inserts. The exterior walls may have a certain taper (8º) to facilitate self-aligning.
Pressure installation
There are inserts whose design allows their introduction without applying heat, we only have to apply vertical pressure to insert the insert gently into the plastic piece. We must have the plastic piece prepared with a hole of diameter determined by the manufacturer of inserts.
Screw installation
This type of insert is also applied cold (does not require heating). To do this, a vertical force is applied and rotated at the same time to gently insert the insert. This union is achieved by flexing grooves that rotate and press the insert against the plastic part.
1. Use of suitable tools such as tips for inserting inserts. And don’t do it directly with the tip of a tin soldering iron.
Considerations
2. Design
a. The depth of the hole has to be greater than the length of the insert, at least 1.2 times.
b. The diameter of the hole in the complement part must be less than the diameter of the pilot to prevent the extraction of the insert.
c. Tapered hole reduces installation time and ensures proper insertion of the insert relative to the hole.
These cannot be used in PULL THROUGH applications or thin-walled holes as they can cause plastic fracture.
3. Slicing Settings (Simplify3D)
Slicing programs usually come configured with 2 or 3 perimeter layers, for these applications we recommend setting the print file to 5 perimeter layers, defining the infill in “Triangle” mode and increasing the% infill depending on the effort to which the insert must be subjected.
Composites at rallycars
It is common in rally cars that some of its components made of pressed steel are replaced by composite materials. Changing the vehicle doors, hood and rear of the vehicle from pressed steel to panels made of a composite carbon-aramid material, reduces their weight between 82% and 89%. Former rally champion Petter Solberg competed in [...]
Screws, nuts and threads in 3D printing
Los tornillos y las tuercas son quizás los elementos de fijación más utilizados en el mundo. Tienen la propiedad de ser uniones reversibles y su principal característica de fijación es la rosca. Las roscas no se encuentran únicamente en los tornillos sino también muchos dispositivos como en engranajes helicoidales, tuberías, etc. Para formar una rosca [...]
HARDTOP in Carbon Fiber for MORGAN 4/4
Lovers of classic cars are in luck with the arrival of new technologies and the customization service provided by engineering companies specialized in 3d printing and carbon fiber such as SUPERCOMPOSITES3D. This time the adventure took place in England. It all started when David Pugh started his personal project on his magnificent Morgan 4/4. [...]
Leave a Reply
You must be logged in to post a comment.