Engineering April 2021
A supplement of Design World
How a new product invention
led to a global manufacturing company
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The wisdom of pre-planning
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It’s unlikely those in the market for a new vehicle are going to ask about the type of fasteners used while on a test-drive (aluminum or steel?), or question the quality of the adhesive used before upgrading to their tablet or smartphone (bonding film or tape?). However, perhaps this should become standard practice. Those in the fastener industry are well aware of how critical these components are to the reliability of an assembly. Although it’s easy to understand the oversight of a consumer — most people only notice the fasteners when they fail. We might also forgive the design engineer, given the significance of the other parts that go into a car or a computer, or other applications. But without the fasteners, there is no assembly. What’s more is that fastening and joining components, if specified incorrectly, can add extra weight and costs to a project, and lead to unnecessary installation time and challenges. Case-in-point: Global fastener manufacturer, Penn Engineering, shares a story on page 110 about a basic keyboard teardown, where their team found hundreds of micro-screws that refused to loosen. “It got us thinking,” said Brian Bentrim, who’s VP with the company’s PEM New Product Development and Product Engineering sector. “Why use screws if you only ever intend to assemble the product and never disassemble it?” As a result, the team developed a new fastener that was intended for permanent use — with a smaller footprint that was less costly, and faster and easier to install. In other applications, choosing the ideal fastening solution early in a product’s development can ensure safety standards. For example, in the article on page 100, adhesive expert Gluespec discusses a new challenge for the electronics sector: the electromagnetic compatibility (EMC) for 5G devices. Although electrically conductive tapes are commonly used to meet electromagnetic interference or EMI shielding regulations, greater precaution is required for 5G applications. This is because 5G’s wireless spectrum is higher than anything that’s come before it. “Tapes that previously worked to pass low or mid-band EMC regulatory tests may fail at this new high-band,” states the article. “Though this is not to say shielding for 5G is insurmountable.” But it is to say that early-stage adhesive considerations are a must, which is something that would be ideal for all fastener applications. With a little pre-planning, smarter designs could also lead to better user experiences as per the article by Southco, a manufacturer of engineered access solutions. Just turn the page to learn more. Thanks for reading! Feel free to share your thoughts or article ideas with us at fasteners@wtwhmedia.com. FE
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How smarter designs lead to better user experiences John Synder • General Manager Transportation • Southco, Inc.
There’s much talk about how digital our world is becoming. It’s easy to point to the smart wireless devices and 5G networks that give us 24/7 access to digital content and tools that have become essential to daily life. Nevertheless, we interact countless times a day with physical items. Systems, equipment, and devices including automobiles, ATMs, lighting fixtures, and everyday appliances are manipulated (opened, closed, adjusted, locked, unlocked, etc.) with little thought by many users as to how these mechanisms provide access. This “touchpoint” experience is often taken for granted. However, the ease and accessibility such mechanisms offer can affect how users perceive the overall quality of their application. Whether it’s a hand-operated latch used to access a vehicle’s glovebox or a counterbalance hinge that holds open a heavy engine hood, a seamless and intuitive user experience is important to ensure quality — and safety. The better the experience for the driver, in this case, the more likely they’ll appreciate their overall vehicle. Small access hardware mechanisms might seem basic but they contribute to the performance, ergonomics, and security of larger applications and can significantly impact the end-user experience. For equipment manufacturers, sometimes this is easier said than done. It involves designing mechanisms to meet the functional needs of the applications while keeping simplicity and ergonomics in mind. Smarter designs can, ultimately, offer a safer, higher quality, and better overall touchpoint for users. 92
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Small mechanisms, such as a hinge installed on a checkout screen at a grocery store, allows for better screen positioning. This leads to a better user experience that’s more ergonomic and easier to read.
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J o i n i n g (such as gas struts) or routine maintenance (such as tightening screws every week or two to maintain hinge resistance), thereby lowering costs. • Eliminate vibration, providing a smooth and steady feel to the opening or closing action.
Redesigning the handle-latch mechanism on a vehicle’s glovebox door can greatly improve its accessibility — and safety, particularly if used while the car is in motion. Engineering the user experience Smaller mechanisms can play a critical role in optimizing a user’s experience of a device. For example, a hinge can change the angle on a self-service kiosk at a convenience store or a touchscreen checkout at the corner market to make it easier and more ergonomic to use. To do so, however, designers must choose the ideal type of hinge to make it easy to change the angle of the touchscreen while holding it in place. The device must also remain sturdy enough so the screen can move, yet stable enough so a customer can easily tap on
the screen to complete their order. A positioning hinge is one example of a simple, yet wellengineered mechanism designers can use to provide ergonomics and ensure the user experiences a quality application. Ideally, its features include the ability to: • Hold doors open or closed, and move panels steadily into position without secondary supports or additional components. • Create an intuitive, zero-drift motion so that when a door or cover is opened, it securely holds a user-defined or predefined position, with one motion. • Eliminate additional components
Hinges designed with integrated constant torque can be added to small panels and doors, providing a smoother, more secure feel when opening or closing. Southco’s ST-7A Constant Torque Embedded Hinge, shown here, features a compact packaging size. 94
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Mechanisms like positioning hinges that change — or elevate — a user’s perception can be applied in several ways. Consider an airplane tray table, for instance. Seating designers must use extremely lightweight plastic components in these applications to help airlines reduce fleet weight and conserve fuel. But a tray table that simply flops down when opened may lead passengers to question the quality of the aircraft or airline. By using a constant torque hinge with a factory-set level of resistance, a passenger can lower the tray with just the right level of force. With this simple design choice, passengers are essentially given a better product and are more likely to have confidence in the quality of the airline and their inflight experience. Sometimes it is the little things that make the difference. What’s more: constant torque hinges designed and manufactured with high-quality materials retain the desired resistance after thousands of flights, without requiring maintenance or parts replacement. Intelligent designs The ideal small mechanism is one that provides the desired function without increasing the efforts required of an end-user. It also means the device is intuitive and easy-to-use without adding unnecessary sizing, weight, or complicated features. Consider the two common storage compartments in the front of a car: the glovebox and the center console. How a driver accesses and DESIGN WORLD
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uses those two compartments is often different. On the glovebox, the latch is typically located in the center of the door. It may have a lock or be unsecured. To open a locked latch, a user would have to turn the car off and remove the key from the ignition. In either case, the driver has to lean over and reach for the latch — something they often can’t safely do while the car is in motion or stopped at a traffic light. A simple design fix: move the latch to the left of the box and closer to the driver to reduce strain and create a more ergonomic user experience. A customized rotary latch with multi-point contact supplies two points of contact to secure the door. Plus, the lift paddle is closer to the driver for easier access. One step above this solution: install a button directly in front of the driver, which opens the glovebox. This more advanced design could use either a mechanical rotary or an electronic latch that’s hidden from view and connected to this button via a cable or direct actuation. To prevent the glovebox door from dropping open, potentially spilling its contents, consider a friction hinge that allows the door to open slowly. It also adds a quality of sophistication to the design that’s likely to improve a user’s overall impression of the vehicle’s make. Additional layers of safety and security can also be included. For example, certain electronic latches can be programmed to avoid opening if the key fob is not present or if the vehicle is moving at a designated rate of speed. The challenge for equipment manufacturers is to define the user experience in terms of function, safety, ease-of-use, quality, and overall impression. Another factor to consider
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for this design process is that gloveboxes may not be routinely accessed as frequently as the center console units. Many drivers open and close the center console to retrieve or put away material multiple times during their commute. Incorporating an access device that’s simple-to-use without the need to glance down at it while driving is key to creating a safe and seamless experience for the operator. The cover should also pop open and stay open until the user is done, and not close due to bumps or vibration caused by the vehicle while in motion. Latches and hinges that are designed to deliver such ergonomic operations can be integrated during the manufacturing process to ensure a driver never has to think twice about how easy it is to access the center console. Repeatability Regardless of what type of equipment or devices manufacturers are providing — aircraft seating, automobile interiors, self-service kiosks, gaming machines, equipment
enclosures for telecommunications, or electrical equipment — offering effective access and positioning control mechanisms are critical. One key is in asking the right questions: How should the mechanism ergonomically open, position, and close a device? What user feedback is needed to accomplish this motion effectively and repeatedly? Repeatability is important in terms of reliability and quality. Whether delivering large volumes of automobile interiors or equipment enclosures, it’s critical that the manufacturer engineers smart designs that deliver reliable performance throughout the lifecycle of the product. These small mechanisms can have a big impact. Ideally, mechanism suppliers and equipment manufacturers must work together to ensure that the right mechanism is delivered to maximize the quality and efficiency of each user experience. FE
Constant torque hinges with factory-set levels of resistance can ensure an aircraft’s tray table releases slowly (without jarring), improving the passenger’s confidence in the overall quality of the airline.
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Five questions
to ask before choosing concrete fasteners Robert Carlisle • President • Concrete Fastening Systems
Fastening to heavy, solid materials, such as concrete or brick, might seem like a challenging task but it’s possible to do so safely and reliably with the right preparation. First, it’s essential to establish the correct information about an application to choose the most effective concrete anchors. This will require an assessment of the material, the weight of the product to be fastened, and the environment where the final application will be placed (including the temperature, humidity, etc). Here are a few important questions to ask before getting started. 1. What is the base material of the product to be fastened? Let’s consider attaching a sign to a solid object as an example. In this case, there are three types of base material to choose from — concrete, brick, or block — and each one has different guidelines to follow for a secure attachment. • If concrete is used, it’s important to avoid setting the fasteners too close together. Typically, these components must be installed about 10 times their diameter apart from one another. Also, avoid placing the anchors within about five times their diameter and from any unsupported edges. • If attaching a sign to brick or block, the fastener can be placed in the mortar joint or directly in either material. The holding values are determined by the quantity and the quality of the mortar if attached within the joint. However, if the concrete fasteners are placed in the brick or block, the holding values are determined by 96 April 2021 www.fastenerengineering.com Materials.4-21_FE_Vs4_MF.LL.indd 96
the quality of the base material and whether the anchor is in the hollow or solid section. 2. How heavy is the product? There is a correlation between the improved holding values of an anchor with the size of its diameter. Generally, the larger the diameter of the anchor and the deeper the depth of the embedment, then the higher the holding value. 3. What is the diameter of the hole? Using the example of the sign, it’s essential to first determine the diameter of the hole in the sign for the correct placement of the fastener. It’s also necessary to ensure DESIGN WORLD
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PEEK, or polyetheretherketone, is a high-performance plastic, making the material ideal for fasteners in many critical or demanding applications.
Choosing the ideal concrete fasteners for securing outdoor controls is critical for the safety, reliability, and longevity of the installation.
that the diameter of the anchor chosen for this application will fit through the hole in the sign. Concrete anchors require a slightly larger hole in the sign than the designated diameter of the anchor. For example, a 1/4-inch concrete anchor requires a 5/16-inch hole in the fixture. 4. What environment will the product be placed in? Safety and reliability are critical for most applications. This means using fasteners that are durable and non-corrosive. Fasteners that are subject to harsh conditions, such as wet or moist environments, can eventually rust or corrode so it’s important to choose wisely.
5. What types of concrete fasteners are available? This question is best asked after answering the previous ones as they will help narrow down the ideal choice. Here are a few options to consider... The wedge anchor: should only be used in solid concrete and never in brick or block. These anchors are offered in several diameters, including from 1/4 to 1-1/4 inches and lengths ranging from 1-3/4 to 12 inches. Wedge anchors are available in zinc-plated, hot-dipped galvanized, and stainless steel. These components typically come complete with a nut and washer, and provide excellent holding values in concrete.
Here are some comparisons to consider before making a choice. TYPES:
APPROVED IN:
USED IN:
304 Stainless Steel
Hot-dipped Galvanized
Submersion, wet environments
Caustic, wet, and/or moist atmospheres
Moist environments
Solid concrete only
Solid concrete only
Solid concrete only
316 Stainless Steel
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The wedge anchor installation process requires a few simple steps: • Drill a hole in the base material, a minimum of 1/2- inch deeper than the wedge anchor’s embedment. Use a carbide bit and hammer drill. • Clean out the hole using compressed air and/or a wire brush. • Place the nut on the end of the anchor before hammering into the hole to protect the threads during installation.
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Two concrete fasteners: a wedge anchor (left) and sleeve anchor (right).
Ultimate load values in 2,000 psi concrete SIZE
MIN. EMBEDMENT
DRILL BIT
PULL-OUT (LBS)
SHEAR (LBS)
1/4”
1-1/8”
1/4”
877
1082
5/16”
1-1/8”
5/16”
892
1156
3/8”
1-1/2”
3/8”
1525
3238
1/2”
2-1/4”
1/2”
2999
5564
5/8”
2-3/4”
5/8”
3749
6198
3/4”
3-1/4”
3/4”
4978
9378
7/8”
3-7/8”
7/8”
6294
13687
1”
4-1/2”
1”
7329
17712
1-1/4”
5-1/2”
1-1/4”
13162
24206
Psi values refer to a compressive strength of concrete using standard cylinders of six inches in diameter and 12 inches in height. The pull-out and shear values for a Confast Wedge Anchor (which are average ultimate values and provide a guide — not a guarantee). A safety factor of 4:1 or 25% is generally accepted as a safe working load. Reference should be made to applicable codes for the specific working ratio.
A Tapcon 410 stainless-steel screw, which can be used in concrete, brick, or block.
• Hammer the anchor through the hole in the sign, as well as into the hole drilled in the base material. Make sure this is deep enough so a portion of the thread is below the surface of the sign. • Tighten the nut three or four revolutions to set the wedge anchor. The correct torque values are typically found in the manufacturer’s manual. Sleeve anchors: versatile fasteners that can be used in concrete, brick, or block. These anchors are available
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in diameters of 1/4 to 3/4 inches and lengths of 5/8 to 6-1/4 inches. Several diameters are available in zinc-plated and stainless steel. There are also several head styles for the sleeve anchors including flat countersunk, round head, and hex nut. The hex nut has the most options in length and diameter. The flat countersunk and round head are only available in 1/4 and 3/8-inchdiameters only. Typically, these anchors come complete with a nut and washer, and their length is measured from underneath the nut and washer. The sleeve anchor installation process is relatively simple: • Drill a hole in the base material, a minimum of 1/2-inch deeper than where the sleeve anchor will be embedded. Remember: the anchor size is the hole size. Use the correct carbide bit and hammer drill. • Clean out the hole of all debris. • Hammer the sleeve anchor through the sign’s hole and into the hole drilled in the base material until the washer is snug with the sign. • First, use your fingers to tighten the nut and then a wrench. But avoid over-tightening or the anchor may spin in the hole. Tapcons or concrete screws: versatile fasteners that can be used in concrete, brick, or block. They’re available in blue Climaseal and 410 stainless steel. DESIGN WORLD
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The standard blue Tapcons come in two diameters: 3/16 and 1/4 inches. The larger-diameter Tapcon is available in 3/8, 1/2, 5/8, and 3/4 inches. These large-diameter screws are only offered in a hex washer head. The length of the screw is determined by the thickness of the sign. The standard blue screws require a minimum embedment of one inch and a maximum embedment of 1-1/4 inches.
• Use a carbide bit and hammer drill. Remember: the hole size should be slightly smaller than the diameter of the screw being used. • Clean out the hole with compressed air and/or a wire brush. • Drive the screw through the hole in the sign using a drill or wrench until snug. If using a drill, avoid spinning the screw too quickly because it might over-torque or strip the threads.
Installing Tapcons is easy: • Choose the proper diameter carbide drill bit and drill a hole in the base material, a minimum of 1/2-inch deeper than the screw that will be embedment.
As with any anchoring project, it’s important to keep safety in mind and follow instructions carefully. Wear safety goggles, handle tools with care, and always refer to the manufacturer’s instructions or consult a contracting expert before beginning an anchoring project. FE
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How adhesive tapes
will advance to meet
5G technologies
Gluespec As of last year, 5G technologies are being built and sold, even though a full 5G global network is a few years away yet. This 5th generation mobile network promises increase speed and reduced latency of wireless services. As with any new technology on the horizon, however, there are potential challenges that the industry is still working on how to address. Electromagnetic compatibility (EMC) for 5G devices is one of those concerns. Electrically conductive tapes for assembly and enclosure-level shielding have been used for years to achieve EMC, but special care must be taken when selecting these materials. The challenge The high-band wireless spectrum that’s been newly allocated for 5G is higher than anything that’s come before it. In fact, it ranges from 20 to beyond 300 GHz. By wavelength, that’s 0.5 to 10mm, hence the name “millimeter-wave” (mmWave). Anything above 18 GHz presents a risk because the wireless signals and noise can interact with the materials in unpredictable ways. For example, adhesive tapes that previously worked to pass low or mid-band EMC regulatory tests may fail at this new highband scale. Except for certain circumstances, when testing materials to work with mmWave or microwave frequencies, circuits operating above 6 GHz are typically not taken into account. This means specification sheets are often unhelpful for applications above 6 GHz. Tapes for electromagnetic interference (EMI) rarely extend ASTM D4935, the common standard for shielding effectiveness, above 10 GHz. This is not to say shielding for 5G is insurmountable. Rather, it underscores the importance of first 100 April 2021 www.fastenerengineering.com Adhesives 4-21_FE_Vs3_MF.LL.indd 100
learning about the new materials and working with qualified specialists to advance adhesives, tapes, gaskets, and epoxy or resins that are suitable for 5G’s millimeter band. Effective 5G EMI shielding is also a challenge because millimeter waves can “leak” into enclosures through seams, joints, hinges, thruholes, or other apertures of submillimeter geometries. Tapes can be used to shore up these ingress points to attenuate external EMI penetrating enclosures. However, other solutions must be used when working with internal interference on the board and with componentlevel EMC/EMI in the millimeter band. DESIGN WORLD
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PEEK, or polyetheretherketone, is a high-performance plastic, making the material ideal for fasteners in many critical or demanding applications.
Special considerations must be taken when selecting the ideal electrically conductive tapes for EMI shielding of extremely high-frequency applications, such as in 5G radio electronics in the millimeter bands or mmWave.
Understanding EMI tapes Here are a few considerations when considering the importance of effective EMI tapes… For gasketing. One important part use of EMI tapes is gasketing whereby vents, thru-holes, or conduits are sealed with gaskets made of materials that offer highshielding effectiveness. Sometimes the tape is die-cut to form the gasket itself. Thick tapes often include carriers, such as foam or rubber, a single-sided metallic coating, and an electrically conductive or insulating adhesive that affixes to internal faces of enclosures around the gasketed punchouts. Additionally, double-backed elastomeric tape is frequently used to adhere and bond specialized
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gaskets for EMI attenuation to metal enclosures. The tape’s adhesive ensures mechanical bonding while the elastomer is impregnated with conductive particles to electrically bond with and conduct EMI from the gasket to shield or ground. For prototypes and shielding repair. Other tapes, made from copper or aluminum films, or flat-woven and braided tapes, are used to increase the shielding effectiveness of an enclosure by applying them across gaps and seams of interior or exterior enclosure surfaces. Although this is more common in prototyping, troubleshooting, and repairs of larger enclosures or high-power wireless devices (as found in RADAR, maritime, avionics, and electrical construction), metallic www.fastenerengineering.com
woven and film tapes occasionally find use in electronic-device production as well. Market potential The age of the millimeter-wave is here, with hundreds of millions of smartphones, tablets, and laptops shipped that have baseband ICs and antennas using 28 GHz and 39 GHz. Moreover, throughout 2021, expect to see miniaturized RADAR at 75-79 GHz enter automotive production lines. The Internet of Things or IoT, which interconnects with 5G, is also expected to pump one-trillion new electronic things into the world in the next decade. And this trillion will all emit electromagnetic interference — and require reliable EMI tapes. FE
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How do
brazing, soldering, and welding differ? Miles Budimir • Senior Editor
Broadly speaking, there are three common techniques for joining metals together, thermally: brazing, soldering, and welding. The three are metal-joining techniques that use heat as the main mechanism to bond two types of metals together. These processes also use some kind of flux to inhibit the oxidation of the metals. However, this is where the similarities end. The differences between welding and brazing relate to two key points: the temperatures used and how the temperatures impact the state of the metals. The main characteristic of welding is that it uses high temperatures of about 1,000˚C (1,832˚F) or higher. One requirement of welding is that the base metals must be similar. So, for instance, steel is unable to weld to copper. It also differs from brazing and soldering in that it’s the only method of the three that melts the base metals and then fuses them with the aid of a filler metal. After cooling, the metals solidify to form a strong bond. This filler metal, sometimes called a “welding rod,” functions in a similar way to solder in brazing. But brazing temperatures are typically much lower than those used in welding. This explains another difference. During brazing, the base metals are not melted — only the filler metal (or solder) melts and spreads out over the base metals, joining them together. The filler metal’s melting point must also be below that of the metals to be joined reliably.
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Welding is an assembly process whereby two or more parts are joined together, typically by means of heat although other Small mechanisms, (such as gas, such as a methods hinge laser, and ultrasonic) installed on a also at available. One checkoutare screen a of theallows main differences grocery store, for betterbetween screen welding and soldering positioning. This or brazing is temperature used. leads to athe better user experience that’s more ergonomic and easier to read.
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Soldering is often used in the electronics industry, typically on printed circuit boards. The solder’s core has a material known as flux, which connects and strengthens electrical bonds. In contrast to welding, however, brazing can be used to join dissimilar metals together such as copper, aluminum, and nickel. In fact, in both soldering and brazing, a metal alloy (or solder) is melted and flows over the two metals to be joined, connecting them together. The main difference between soldering and brazing is the temperature. The American Welding Society defines brazing as the process where the filler metal (i.e. solder) has a liquidus above 425˚C (800˚F). This means it becomes liquid or melts at temperatures above this point and begins to solidify below that temperature. Soldering, on the other hand, involves filler metals with a liquidus below 450˚C (842˚F). In brazing, the most common heat source is a gas flame torch. Additional methods include furnace brazing, dip brazing, electron beam, laser brazing, and others. For soldering, the most common technique is to use a soldering iron.
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Other techniques, such as reflow or wave soldering, are used in highvolume manufacturing environments. Brazing and soldering use flux as a part of the process. It’s used to clean the metals to be joined, removing any oxidation and preventing any from forming. Using the best flux for the job means ensuring that it’s chemically compatible with the metals and the solder. For instance, flux used in electrical soldering typically contains a rosin core, whereas flux for brazing applications might use borax or other compounds. Generally, soldering is used in electronic applications, primarily to make an electrical connection. So, it’s not as mechanically strong as a brazing joint, which ensures a much stronger bond between metals. Brazing also requires the parts to have a tighter fit than soldering to form a strong connection. The most common brazing method is torch brazing, which uses a gas flame. Other common
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techniques include furnace brazing, which is conducive to industriallevel mass production applications. As for the strength of a bond, a properly welded joint will typically be stronger than a brazed joint. However, a proper brazed joint will still be stronger than the individual pieces joined together. FE
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“Family
is our Fastener” Industrial Rivet celebrates more than 100 years of success Michelle Froese • Editor When Taryn Goodman’s great grandfather (Willie Goodman) founded Industrial Rivet & Washer Co. in 1912, he likely never expected the company to last more than 100 years or to maintain one of the industry’s largest inventories. He was simply offered an opportunity to sell rivets in New York City and grew to become an expert in riveting. Today, his company offers more than 1.4 billion pieces of highquality rivets, in addition to automated riveting tools, delivery systems, and other related services. Willie also likely never expected his great-grandchildren to join the business — now known as Industrial Rivet & Fastener Co. “We’re currently a fourth-generation, family-owned business,” shares Taryn Goodman, VP of finance, though she also handles the marketing and administrative responsibilities. “That includes me and my cousin, Steven Sherman, who’s the company VP and head of R&D and Engineering.”
Taryn Goodman, VP of finance at Industrial Rivet & Fastener Co. She’s also a volunteer director with Women in the Fastener Industry or WIFI, which provides opportunities for women in the industry to connect, network, and learn from one another. 106
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Goodman’s dad, Bill, is the president. Bill co-owned the company with his sister (Sherman’s mom) until she sadly passed away in 2016. The two had taken over the business from their father (who still works in accounts receivable at age 90, sharing an office with Goodman), which is now headquartered in New Jersey. “So, it’s essentially three of us at the helm now and we’re really an amazing DESIGN WORLD
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team who all work well together,” she says. “Working here was one of the best decisions I’ve ever made.” Industrial Rivet was not on Goodman’s radar in her youth. She occasionally chipped in, filing and doing data entry work, but never expected to make it a career. She went to Williams College, earning undergraduate degrees in biology www.fastenerengineering.com
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The team at Industrial Rivet & Fastener Co. From left to right: Joanne Sherman, Bill Goodman, Allen Goodman, and Steven Sherman.
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The RivetKing FreeSet’s blind rivet and rivet nut tools.
“Education is important because fasteners are often the last components considered for an application. Companies will often just head to their supply room to check what parts they have left over from another project...”
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and economics, and later an MBA at Wharton at the University of Pennsylvania. She planned to become a doctor until fainting while watching a surgery during her undergrad — hence, the MBA. “On a whim, I applied for a job in finance during my junior summer of college and got an internship at Lehman Brothers in New York City, which I loved. They even offered me a full-time job after I graduated,” she says. The gig began in the fall of 2008. Two months into her new career, however, the finance company was near collapse thanks to the recession and was bought by the investment firm, Barclays Capital. “In many ways, I was fortunate. Barclays kept me on and I learned a lot in a couple of years. I experienced two different company cultures and practices, and then watched them merge into one,” she says. “I enjoyed it but knew it wasn’t what I wanted to do www.fastenerengineering.com
forever. We’d advise all of these companies because that’s what you do in investment banking, but I never got to see it through or learn the final results. I felt something was missing.” Eventually, Goodman approached her family for advice. In 2012, she officially joined Industrial Rivet & Fastener Co. “I love coming to work every day. It’s truly the best,” she says. “Although, I admit I didn’t have all that much fastener knowledge coming into the job, which was somewhat surprising given I had grown up with the company.” But Goodman was a quick study and was impressed with how the business was run. Still, she wanted to take things to the “next level.” “In our parents’ generation, the company was well-known as the ‘supermarket of rivets,’” she shares. “Most rivet companies offered only one type of rivet but DESIGN WORLD
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we manufactured and sold several different types, so we became true experts in permanent mechanical fastening.” Much like other fasteners, rivets have to fit the application correctly. But, as Goodman points out, they also have to function correctly. “It’s not like with a nut and a bolt, where you can re-install the components by unfastening and re-fastening. When you set a rivet, you’re changing the shape of it and it’s meant to set permanently. If you have to take it out for some reason, the rivet is damaged — and, potentially, so is the application that it was holding together.” To provide the correct rivet and installation instructions for multiple applications, the team at Industrial Rivet must be extremely knowledgeable. It’s not always an easy match. Goodman says one of their goals was to go from being a one-stop supermarket of rivets to one that also provided engineered solutions. “We, of course, still offer many types of rivets but we also put a strong focus on our engineering capabilities to help customers solve their problems — and their customers’ problems,” she says. “We’re continually assessing what’s the ideal rivet for a certain application and what’s the most efficient way that we can manufacture it.” Industrial Rivet’s extensive manufacturing network means the company can design, manufacture, and engineer custom and readymade products for a global customer and distribution base. They also conduct salt-spray analysis, shear and tensile testing, and dimensional verification to ensure fastener reliability. In fact, the company has an ISO-certified lab, where they also offer hardness (B, C, and V) testing for maximum durability.
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“Education is so important because fasteners are often the last components considered for an application. Companies will often just head to their supply room to check what parts they have left over from another project, and manage with those,” she says. “It’s natural to want to save costs and use up resources, but those components might not be the best fit, which can lead to problems.” Fortunately, Industrial Rivet offers options and support, including advanced riveting tools to help with installations. “One of the most exciting things for me in this business is rolling out new technology. It’s something I didn’t get to experience in my previous career…to be involved from the inception of an idea to its production,” says Goodman. “I now get to see the final results.” The RivetKing KingSet is one example, an innovative handheld riveting system that Industrial Rivet developed for more efficient installations. The KingSet has autofeed capabilities that let operators align workpiece holes in one hand, while riveting with the other hand, for faster and easier assemblies. It’s also fully portable and can be suspended horizontally or vertically, so it adapts to different manufacturing environments. The company also offers a RivetKing FreeSet series of cordless riveters that operate on par with or sometimes even faster than pneumatic tools. They also use 99% less energy than air compressors and can significantly reduce a company’s CO2 footprint. “We’re continually focused on becoming a more efficient and advanced company over time,” she says. “I mean sometimes it’s challenging when you’re more than 100 years old and used to doing things in a certain manner. But, in www.fastenerengineering.com
many ways, we’ve always been cutting-edge for this industry, which is often slow to adopt.” Goodman says the company runs digitally and has been paperless for close to 20 years, plus much of their equipment and facility is automated. Industrial Rivet was deemed an essential manufacturer and has remained operational since the COVID-19 pandemic hit. “Thankfully everyone has remained healthy and employed here, with some basic changes in shifts and practices to meet the safety guidelines,” she says. “It would’ve been heartbreaking otherwise. We are a family-owned business and the people who work with us are all like family. It’s got that kind of feeling and atmosphere.” The feeling is so strong that Industrial Rivet even trademarked the term: Family is our fastener. “Family is what holds this company together, whether that’s our actual family members or our extended family of employees, sales reps, partners, and customers,” says Goodman. “I even have it tattooed on my foot, which my cousin likes for me to show off at business meetings, to show our true values!” FE
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J o i n i n g
How a new product invention led to a global manufacturing company
Michelle Froese • Editor With a workshop of sorts set up in his garage, K.A. Swanstrom developed a revolutionary product in the early 1940s — one that would reduce time, labor, weight, and inventory on many assembly jobs. This new self-clinching fastener was easy-to-install and provided load-carrying threads in the metal sheets that are too thin to be tapped. In 1942, Swanstrom officially founded PennEngineering & Manufacturing Corp., which today is a global company that manufactures a variety of mechanically attached fastening solutions. “The way I understand it is that our company founder began making weld nuts in his garage and slowly integrated this process into clinch nuts, which offer a different way to connect the nut to a piece of sheet metal. He then turned that idea into the worldwide business that we have today,” shares Brian Bentrim, VP, PEM New Product Development and Product Engineering, with Penn Engineering. Based in Pennsylvania, Swanstrom worked as the president of Elastic Stop Nut Corporation, when he left to form PennEngineering.
Brian Bentrim, VP, PEM New Product Development and Product Engineering, with Penn Engineering.
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“When he was looking to move from his garage to a bigger space for the company, Swanstrom was in the Doylestown area. Apparently, he started driving out of town, following these three-phase wires that were attached to telephone poles and secure electricity on the side of the road,” says Bentrim. Telephone poles either have a pair of wires at end of their T-shape or a third DESIGN WORLD
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wire that sits on the top of that ‘T.’ “The ones with the three wires allow more power to carry across the electrical connection, which is often needed for heavy equipment,” he explains. “Essentially, Swanstrom followed these connections until he found a plot of land for sale beside the three-phase wires. Our corporate headquarters, with now larger www.fastenerengineering.com
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PEM brand fasteners use self-clinching, broaching, flaring, surface-mount, or weld technology to provide strong, reusable, and permanent threads and mounting points in sheet metal, P.C. board materials, and other ductile or non-ductile thin material.
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PennEngineering’s Danboro, PA headquarters.
“In my experience, nothing motivates engineers to push a project more than if it’s one of their ideas and something they want to run with, develop, and prove.”
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production facilities, are still in the same location.” Swanstrom’s self-clinching fastener proved extremely successful at the time and its technology is still commonly used today. As the need to hold ultra-thin and ultra-light metals together grew, particularly in the electronics industry, so did the product line. Over the years, the original design has been modified to meet hundreds of new applications. “At first, an electrical current was used to melt the nut and form a weld in the fastener. But then, Swanstrom realized that it was possible to design a geometric shape within the fastener and push it against the sheet metal, which would cause the sheet metal to flow and permanently deform against the nut,” says Bentrim. By using this application, it was possible to lock the nut onto the sheet metal. “Technically, the clinch nut was our first innovative product but second product line. The weld nut would have been the first product line,” he says. PEM, the company’s www.fastenerengineering.com
leading brand, has been recognized as the premier product in the thinsheet fastening industry for more than 75 years. “And since then, we’ve developed hundreds of innovative product lines. We continually look for different ways to solve problems in fastening and joining.” One example of that innovation, according to Bentrim, is the R’ANGLE clinch fastener, which offers strong, right-angle attachment points in sheet metal or PC Boards. It uses the same technology as the clinch nut but instead of placing the nut directly against the sheet metal, it places it 90 degrees to the sheet metal. “The R’ANGLE has a very PennEngineering, iconic shape to it and is used to mount a second sheet perpendicular to the first sheet,” he says. The benefits include tighter design control, material savings, fewer assembly steps, and a reduction of loose hardware. PennEngineering is a major supplier to the electronics and consumer electronics industries. However, it also serves the automotive, transportation, DESIGN WORLD
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agriculture, construction equipment, special industry machinery, marine, alternative energy sectors, HVAC, and others — and almost anywhere in the world. The company is also continually working to improve these industries with advanced fastening solutions. “We often ask ourselves: what are the problems that are being faced today in fastening and how can we better address those?” he says. “It’s ideal when a customer comes to us with a problem to solve but, to be honest, we’re always doing our own teardowns of equipment in an attempt to stay current on the different technologies and applications used…and to figure out if we can offer something better.” Better could mean fewer parts, less costly parts, or an easier assembly method. Case-in-point: several years ago, one of the PennEngineering teams took apart a keyboard. “Immediately, we noticed all of these tiny micro-screws that were maybe 1.6-millimeter-diameter threads. Each one had a locking patch with near-microscopic drivers on. So, when we went to take these hundreds of screws out, most of them refused to budge,” Bentrim explains. “They were permanently locked in.” The team immediately began brainstorming. “It got us thinking: why use screws if you only ever intend to assemble the product and never disassemble it?” As a result, they developed a new fastener that was intended for permanent use. “Instead of drilling a hole that was tapped and then requiring a screw that had a patch on it with a big head and a driver, we just pushed it in a simple little tack pin, which eventually became the microPEM TackPin. It had a shorter head and worked in a shallower hole, which led to a stronger hold and a smaller footprint.” According to Bentrim, it was also less costly, faster, and easier to install.
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His team took the disassembled keyboard to the OEM to show them the new fastening option. “They didn’t say too much at first but about 18 months later, they called us back and asked to take another look. Since then, we’ve sold billions if not hundreds of billions of these fasteners,” he says. PennEngineering was able to increase the strength and reduce the thickness of these keyboards. And keyboards are not the only product with a similar setup. Yet, the most common way of putting something together is a screw. “We continuously see people putting together products that are never intended to be disassembled… meaning that if it breaks, you’re likely going to replace and not repair it. This includes the subcomponents of a computer or a car stereo. Very few people will try to repair the actual sub-component because it’s cheaper or easier just to replace them,” he says. However, as Bentrim points out, there’s a lot that goes into the fastening of a screw. It requires a nut or a threaded hole, which then needs to engage and turn together. Torque is also often important to control. “If you don’t need to take it apart, there’s a simpler way to achieve that joint. You don’t need a screw,” he points out. “But generally, this is the last thing on a person’s mind when they’re designing an application. However, it’s what we do and do well.” Bentrim says one of the best parts about working at PennEngineering is the freedom and flexibility to try new ideas and create new solutions. “In my experience, nothing motivates engineers to push a project more than if it’s one of their ideas and something they want to try to run with, develop, and prove. I www.fastenerengineering.com
allow my team as much flexibility as possible to think creatively and test out their ideas.” This is particularly true from an R&D perspective, adds Bentrim. “People typically don’t think of fasteners as all that interesting or exciting. But fasteners enable all of those exciting, smart, and sexy gadgets by holding them together,” he says. “By pushing the boundaries of what you can do with a fastener… well, that makes this job a lot of fun.” FE
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J o i n i n g
The growth of a global
go-to adhesives company
Michelle Froese • Editor Brandon Willis had a year of challenges in 2020 — but good ones. Despite the pandemic, he relocated to a new state with his family, bought a new home, and started a new job with an impressive role. “I started with Epoxy Technology on September 1st of last year,” he says. “I’ll admit it was a little stressful because the timing was extremely compressed but it’s worked out incredibly well.” Willis is the new president of the Electronics Division of Meridian Adhesives Group, of which Epoxy Technology, Inc., a manufacturer of specialty adhesives for advanced tech, is one company. However, his role also covers Epoxy Technology Europe and Epoxies, Etc., a manufacturer of customized epoxy, polyurethane, and silicones for a variety of industries. These companies, including several others, fall under the portfolio of Meridian Adhesives Group, a U.S.-based manufacturer of high-performance adhesives and sealant technologies. Brandon Willis, president of the Electronics Division with Meridian Adhesives — which includes Epoxy Technology in its portfolio.
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An encapsulate or potting compound used for an electronic circuit board.
With extensive adhesive experience and a B.Sc. degree in chemistry, it’s obvious why Willis was chosen for the job. “I’m a chemist by trade. I started out formulating polyurethane coatings for the automotive industry…and worked my way up through the technical ladder until I was managing R&D.” His career began at Indianabased Red Spot Paint & Varnish Company, which develops highly engineered performance coatings. “Eventually, I was asked to take over the marketing and product management, and then I took over business development. When I left there, my title was somewhat all-encompassing as a commercial manager.” Willis spent about 17 years at Red Spot before moving to Uniseal, Inc., a provider of epoxy, PVC, and rubber-based adhesives to the global transportation sector. After only three years at Uniseal, he was chosen as the company’s third president in over a half-century of operations. “We developed high-strength, structural adhesives for automotive bonding. Most people don’t realize that their cars are, for the most part, glued together,” he laughs.
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After a decade at Uniseal, he led that company through a major acquisition. “We were purchased by LG Chem in 2018 and I helped lead that process and integration of the company.” LG Chem is currently the 10th largest chemical company, worldwide. Then, Willis heard about the position with Meridian, managing multiple companies. “The opportunity just felt right and, to be honest, I’m excited about the challenge. I enjoy working at a fast pace and supporting and experiencing the growth process of a company, which includes acquiring new businesses — and that’s what we’re building on here,” he shares. “We aim to be the go-to adhesives company in the electronics space.” Currently, Meridian owns 11 companies and counting. Epoxy Technology is one that was originally founded in the ’60s by Frank W. Kulesza, a chemical engineer who had experience working at electronics company, IBM. As a pioneer in the conductive adhesive industry, Kulesza sought to replace eutectic bonding in hybrid microelectronic assemblies. “This was in 1966 and Epoxy Technology was one of the
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first companies to successfully manufacture specialty, epoxy products that were electrically conductive,” says Willis. In fact, Kulesza’s goal was to completely replace eutectic bonding (or soldering) in hybrid microelectronic assembly. He eventually formulated and shared what has become some of the most relied upon epoxy adhesives, which are still in use today. “He basically developed custom-formulated products that helped PCB manufacturers build electronics,” says Willis. “At that time, such components were soldered together. So, the idea of using a conductive paste or adhesive to replace solder was quite novel.” As one example, this included developing a silver-conductive adhesive for use instead of solder for radio transmitters and receivers, radar, and Satcom devices. Since then, the company has expanded and the product lines have grown extensively to meet several different requirements. “There’s been a tremendous amount of advancement in terms of the durability of the materials and the performance requirements. Where at first, it was mostly about manufacturing an adhesive product that could be used in electronics to replace soldering, it has become more about formulating products that can resist shock or vibration and endure extremely harsh conditions,” explains Willis. Just think of your smartphone that can now withstand the shock of being dropped, or hours of moisture and cold if you’re outside (say hiking) 116
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The careful dispensing of an adhesive onto an optical filter and into the perimeter ring housing relies on advances in micro syringes. with it on a rainy day. “At the same time, these formulas must remain thermally and electrically conductive and meet the ongoing trend of miniaturization,” he adds. “As the components get smaller and smaller, performance must increase from a process standpoint, which leads to a lot more heat generation. So, we’ve had to formulate products that are very good at removing heat from the critical components that are inside electronic devices.” What’s more, is changes in the application methods have had to follow suit. Where once a simple, large drop of adhesive from an applicator could work on a component, miniaturization fails to allow for such simplicity. “Now, we’re primarily using micro syringes and micropipettes to get the droplet size as tiny as possible so they don’t take up precious real-estate on printed circuit boards,” he says. “This requires specific formulations and precision. But it’s worth it because of the advances…I mean who would have thought we could carry around a computer in one of our pockets that’s capable of so much?” Epoxy Technology covers more
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than smartphones and computers. Its products are also largely found in medical devices, automotive electronics, fiber optics and optoelectronics, photovoltaics, as well as some in the military and aerospace sectors. One major advancement was the company’s EPOTEK 353ND, which is now typically recognized as the go-to adhesive for fiber optics. “One of its original applications was for endoscopes used in hospitals, which require flexible fiber optics to work,” explains Willis. “EPOTEK 353ND is used in bonding the fiber into ferrules, allowing the transmission of light in the 800 to 1550nm range.” This adhesive’s exceptional optical properties have since enabled the use of advanced endoscopes, which have led to cutting-edge surgery practices in the medical field. “Our primary business is solving problems,” he shares. “Most of the requests we receive are for specific applications that require some form of customization. For example, this could be meeting a set curing window for an epoxy formulation because timing is an issue. Most
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of what we offer is individualized for a set user and we have a small, but talented R&D team that does exceptionally well.” Within these parameters, Epoxy Technology is also dedicated to meeting the high standards of ISO 9,001 certification for quality management, MIL-STD 883/5011 military certification, and is RoHS Compliant in relation to hazardous substances. “We’re environmentally conscious and have tried to stay ahead of the curve, which means we don’t use heavy metals, hazardous materials, and nearly zero solvent,” he says. “This brings added challenges when formulating products but it’s well worth it. We’re also a part of the Sony Green Partnership.”
This program supports the production of environmentally safe and sensitive products. Of course, it helps to be part of a global adhesive umbrella under Meridian, which provides access to a wider portfolio of products, expertise, and support. “We’re of the mindset that it takes a village,” says Willis. “So, building out a supportive network that can supply the products and standards customers request within their required timeframe is extremely important to us. And we want to be as flawless as possible in that approach to ensure success for everyone.” FE
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Selecting the Optimal Washer Flat: Generally used for load disbursement Tab/Lock: Designed to effectively lock an assembly into place Finishing: Often found on consumer products Wave: For obtaining loads when the load is static or the working range is small Belleville: Delivers the highest load capacity of all the spring washers Fender: Distributes a load evenly across a large surface area Shim Stacks: Ideal for simple AND complex applications
Boker’s Inc. 3104 Snelling Avenue Minneapolis, MN 55406-1937 Phone: 612-729-9365 TOLL-FREE: 800-927-4377 (in the US & Canada)
bokers.com
Structural Adhesives for Specialty Trucks and Trailers Many truck and trailer manufacturers are making the switch to adhesives instead of traditional welding and fastening. Lowering fuel cost, wind drag, and weight has become an important component in manufacturing specialty vehicles. Several trial applications have been performed, and results have shown that the bond of structural adhesives are stronger and more reliable. Ellsworth Adhesives offers a variety of acrylic, epoxy, and urethane structural adhesives. Structural adhesives can be used to configure work truck equipment, trailer assembly, and aftermarket upfitting. Applications can range from panel bonding for trailers, installation of tool boxes in construction trucks, shelf hanging for delivery vehicles, plumbing equipment for firetrucks, to electrical components in utility vehicles.
Ellsworth Adhesives Ellsworth.com (877) 454-9224
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Keystone Electronics Corp. A World Class Manufacturer of precision electronic components & hardware for over 70 years. Keystone’s design and engineering experts are fully integrated with their in-house precision tool & die division supported by advanced manufacturing systems to produce close tolerance Stamping, Machining, Assembly, CNC and Injection Molded parts. Keystone utilizes state-of-the-art software to support the thousands of standard products found in their Product Design Guide M70 and Keystone’s Dynamic Catalog on-line. Product Overview: Battery Clips, Contacts & Holders; Fuse Clips & Holders; Terminals & Test Points; Spacers & Standoffs; Panel Hardware; Pins, Plugs, Jacks & Sockets; Multi-Purpose Hardware. As an ISO9001:2015 certified manufacturer, Keystone’s quality control system, responsive customer service and custom manufacturing division can meet your challenges with a standard or custom design solution. DESIGNERS & MANUFACTURERS
Keystone Electronics 55 S. Denton Ave. New Hyde Park, NY 11040 Tel: 1.800.221.5510 www.keyelco.com
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Pivot Point, Inc. The SLIC Pin™ from Pivot Point is a pin and cotter all-in-one. An excellent alternative to installing e-clips and secondary cotters, the patented SLIC Pin features a spring-loaded plunger which acts as an automatic cotter pin. SLIC installs faster and more consistently than two-piece combinations – increasing productivity, cutting labor costs, and reducing risk of mis-installation and accidental disengagement. Simply depress the plunger with your finger or a tool in order to remove the pin. Use our “removable” style plunger if removing through small gaps. SLIC Pins can be made in virtually any material and finish. Millions of SLIC Pins are installed every year across all industries. Contact Pivot Point for free samples and information.
Pivot Point, Inc. www.pivotpins.com PO Box 488 Hustisford, WI 53034 761 Industrial Lane Hustisford, WI 53034 800-222-2231
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