FASTENER ENGINEERING JULY 2020 by WTWH Media LLC

Engineering

A supplement of Design World

The design, materials, and stories behind the fastener industry.

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EDITORIAL •• •• •

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A local business down the street from me has a large sign out front that says: “Nothing’s for sure that’s for sure…but we’re reopening June 15.” However, the date has been crossed out and underneath it states, “likely sometime in July.” As businesses begin reopening, there are undoubtedly mixed feelings including skepticism and cautious optimism. Uncertainty is a powerful thing. Although there’s no playbook on dealing with a global pandemic in 2020, there are companies that have learned a thing or two since the government-mandated shutdowns. That’s because these companies never closed their doors. Several fastener manufacturers and distributors, deemed essential, have remained operational despite the risks — and deserve full praise. Many have stepped up to the challenge, mass-producing parts to meet the demands for medical device components, such as for ventilators and hospital beds. Others have continued to supply critical components to the food, power, water, transportation, and other vital sectors. Now, these companies are in an ideal position to share the tips and knowledge gained during the past few months. For example, flexibility has been key for Meridian Adhesives Group, a U.S.-based holding company for adhesive manufacturers. This has meant creating a contingency plan for unexpected or unfortunate events. So, they’re now prepared for a temporary closure of their facilities without disruption — say, for environmental cleaning and disinfection — if this becomes necessary. For Southco, a global designer and manufacturer of access hardware, ensuring at least two suppliers are available for every process has been important so they are never singlesourced or left without options for continued operation. “The planning ahead is what’s important here,” says the company. Advance Components, an industrial fasteners master distributor, suggests investing in a risk-assessment plan. This is a strategic plan that ensures operation and a secure supply chain in the event of an emergency. “We initially foresaw this as planning for an accident… such as a storm, fire, fraud, or theft,” shared the company president. “We didn’t foresee a global viral pandemic wreak havoc on everything. But fortunately, the solutions we put in place helped us be very prepared.” For SPIROL, a global manufacturer of precision engineered components, maintaining positivity has been imperative: “We’ve been circulating success or feel-good stories every couple of days….it’s important employees know that while the world may be turned upside down, there are some great things that are happening every day, too!” Read the full interviews by clicking on the COVID-19 link at fastenerengineering.com. We wish you all great things despite the current uncertainties. Stay safe!

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Why plastics are the

material of choice for most fasteners Barbara Gerard • CEO • Craftech Industries, Inc. Plastic materials are quickly gaining credibility in the fastener industry and for good reasons. Plastic fasteners are strong yet flexible, durable, cost-effective, and they fail to rust, which is a big plus. PEEK, also known as polyetheretherketone, is one type of plastic that offers highperformance engineering and versatility. This material has an extremely stable chemical structure that’s rare to find in other plastics, making it ideal for use in fasteners in several applications and industries. For example, PEEK is often used in components for the automotive, aerospace, marine, nuclear, oil and gas, and in the electronics sectors. It’s also considered an advanced biomaterial and medical implants are made from it. As a result, it’s increasingly used in spinal fusion devices and for reinforcing rods. Additionally, PEEK fasteners are used in the food and beverage industry for food and feed drying. Clearly, this material is versatile and reliable, even in demanding applications. Aside from fasteners, parts such as bearings, pumps, pistons, compressor plate valves, cable insulation, and others use PEEK. Key features PEEK is a semi-crystalline, high-temperature resistant thermoplastic. The processing conditions used to mold it can influence its crystallinity and mechanical properties. Its Young’s modulus (this is the mechanical property that measures the stiffness of a solid material) is 3.6 GPa and its tensile strength is 90 to 100 Mpa. PEEK has resistance to hydrolysis so it’s unable to absorb water. This makes it highly tolerant to thermal degradation and attacks by organic and aqueous environments. A few other features are that it’s susceptible to halogens and strong Bronsted and Lewis acids, as well as some halogenated

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PEEK, or polyetheretherketone, is a high-performance plastic, making the material ideal for fasteners in many critical or demanding applications.

compounds and aliphatic hydrocarbons at high temperatures. (Lewis acid accepts a pair of electrons while a Bronsted acid accepts pairs of electrons at an acidic hydrogen.) PEEK is soluble in concentrated sulfuric acid at room temperature. The material also has superior creep resistance, serving as a high-strength alternative to fluoropolymers. Environmental considerations PEEK has a glass transition temperature of 289° F (143° C) and melts at 662° F (343° C). Some grades have a continuous operating temperature of up to 482° F (250° C). Aside from being resistant to organic and aqueous environments, it’s also highly resistant to thermal degradation. PEEK has a UL flammability rating of V-0 and exhibits low smoke and toxic gas emissions. The plastic resists radiation and a wide range of solvents. It can withstand boiling water

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Several grades of customized PEEK fasteners are available commercially, depending on the application. www.fastenerengineering.com

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Fastening + Joining and the super-heated steam used with autoclave and sterilization equipment at temperatures higher than 482° F (250° C). Grades The unfilled grade offers the highest elongation and toughness of all the grades of PEEK. It is available in light brown or tan and black. Reinforcing fibers are often added to plastic resins to increase the tensile strength and flexural modulus of the composite. • PEEK 30% glass-filled includes glass fibers as an additive. This grade is ideal for structural applications that require improved strength, stiffness, or stability at temperatures of about 300° F (150° C). This grade dramatically lowers the material’s expansion rate and increases its flexural modulus. Glass-filled PEEK is light brown or tan.

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• PEEK 30% carbon-filled uses carbon fibers as an additive. The carbon fibers enhance the compressive strength and stiffness of the material and dramatically lowers its expansion rate. This plastic material grade offers optimum wear resistance and excellent load-carrying capability. PEEK 30% carbon-filled provides threeand-a-half times higher thermal conductivity than the unfilled grade. Therefore, it dissipates heat from the bearing service faster. PEEK 30% carbon filled is black. • PEEK (Bearing Grade, Ketron HPV) is a grade that’s reinforced with graphite, PTFE, and carbon fibers. This grade offers the lowest coefficient of friction and the best machinability of all the PEEK grades. The bearing grade, Ketron HPV sports an excellent combination of low friction and wear, high limiting PV, low mating part wear, and easy machining. This grade is black or dark gray. Thanks to several of PEEK’s properties, the plastic can serve as an alternative to steel, aluminum, and brass fasteners. A summary of its benefits includes resistance to high temperatures, chemicals, hydrolysis (exposure to steam or high-pressure water), and fire. PEEK fasteners can also withstand forces (such as stretching and pulling) and abrasion, making them ideal for nearly every industry.

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How to choose the ideal adhesive for an application Julie Miller • Writer

Engineers are increasingly relying on adhesives as alternatives to mechanical fasteners. They offer several advantages that typically include a lighter-weight assembly, fewer individual components, and faster production. Adhesives also offer the ability to join dissimilar substrates. However, choosing the correct adhesive is critical, particularly given the variety of choices and features available. Load-carrying capacity is often the deciding factor in choosing a product for a particular application. The load-carrying capacity is defined by the maximum load an adhesive-bonded joint can bear without failing.

If using tape, it’s important to apply an adequate amount of pressure to ensure it fully adheres to the application and fills the gaps between surfaces. 78

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When considering loadcarrying capacity, adhesives can be categorized as: • Structural • Semi-structural • Non-structural Structural Structural adhesives demonstrate strengths from 1000-pound-force per-square-inch (psi) up to as high as 4000 psi. Generally, they offer sufficient strength and durability to tolerate environmental exposure and maintain performance integrity when a bonded joint is stressed to its yield point, at least within the given design limitations. Because of their high strength, structural adhesives are used for long-term, permanent attachments. Sectors such as the automotive, aerospace, construction, consumer appliance, electronics, medical device, and other critical industries DESIGN WORLD

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rely on structural adhesives — generally, as an alternative to mechanical fasteners. The advantages of structural adhesives include: • Reduced assembly size and weight • Fewer parts per assembly • An ability to join dissimilar materials • Adaptability to automated processes • Productivity gains with fast-setting formulations • Improved aesthetic design • Lower cost Another advantage of structural adhesives is that they provide strong attachments for a variety of substrates, including metal, composites, and rigid and flexible thermoplastics. Additionally, structural adhesives can

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fill gaps between substrates, sealing out environmental exposure. Chemistries of structural adhesives include acrylics, cyanoacrylates, epoxies, rubber, and urethanes. With liquid or paste application, a consistent bead of adhesive on the substrate ensures the strongest bond. The application of liquid-type adhesives ranges from contact-bond and hot-melt to aerosol and cylinder spray. Tape or film formats are also appropriate in some applications, where the right amount of pressure must be applied to ensure the tape fully adheres and fills the gap between surfaces.

Structural adhesives are generally easy-to-use and cost-effective compared to mechanical fasteners because of the reduced material costs, parts, labor costs, and process time.

Semi-structural Semi-structural adhesives are strong, but many cannot maintain their load-bearing support continuously for long periods without www.fastenerengineering.com

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deformation or failure. These adhesives might be used for short-term or temporary attachments, such as keeping substrates in place in preparation for a subsequent process. However, recent advances in bonding technology have given rise to higher-performance products that can withstand harsher conditions or environmental exposure. They’ve also developed formulations that are easier to apply. The chemistry of semi-structural products overlaps with their structural and non-structural counterparts, such as pressure-sensitive and contact adhesives, hot melts, polyurethanes, and other polymers. Aside from load-carrying capacity, several features should be considered when choosing a semi-structural adhesive, depending on the intended use. • Structural adhesives. Some products have a limited shelf or working life. Adhesives might be repositionable with varying degrees of tackiness. Others may offer short setting times, calling for immediate attachment of the substrates.

Delivery mechanisms include thin-to-medium liquid or paste formulations. Liquid-types can be applied with a brush or roller, via aerosol spray or as a hot-melt formulation that hardens when cool. The advantages of using non-structural adhesives instead of mechanical fasteners include quick assembly, lighter overall assembly weight, and aesthetic design that avoids holes or visible fasteners. In some cases, water-based non-structural adhesives can replace solvent-based products for greater compliance with safety and environmental standards. However, non-structural adhesives are a poor choice for joining materials that will endure exposure to high or low temperatures, moisture, radiation, acidity, alkalinity, and bio-agents. In addition to load capacity, designers should also consider the potential for shear, compression, and cleavage of the joint. For applications that require more strength or more durable bonding, structural adhesives or mechanical fasteners are recommended.

• Adhesion application. Adhesives might require the application of heat to set the bond. Additional time, processes, or equipment may also be needed. • Cost. It’s important to select an adhesive that meets the requirements of the design, but overall costs should also include labor or possible downtime while an adhesive application sets. • Aesthetics. Engineers should consider how the applied adhesive might appear in the final assembly. With some products, creep is possible, causing the adhesive to be visible beyond the substrate.

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Non-structural Similar to structural adhesives, non-structural adhesives can provide attachment between dissimilar substrates, such as paper, cardboard, foam, metal, and plastic. But they are better suited to applications that are not exposed to harsh conditions or extended environmental exposure. The temperature resistance of non- structural adhesives is typically below 200° F (93° C). Many nonstructural adhesives are repositionable with varying degrees of tackiness, while others offer drying times as short as one minute.

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Ultrasonic welding

A versatile technology used in the fight against COVID-19 Tarick Walton â&#x20AC;˘ Global Product Manager, Ultrasonics for Assembly Technologies â&#x20AC;˘ Emerson

The components of an ultrasonic welding system.

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Ultrasonic welding is a fast, energy-efficient, and permanent fastening method used to join plastic parts and materials. Different variations of this technology are used to bond rigid plastics in automotive components, medical devices, electronic products, and many types of consumer goods. Ultrasonic welding is also necessary for bonding clear film in packaging and tamperresistant containers used in the food, beverage, and packaging industries. The versatility of his type of welding is evident as it also provides efficient, corrosionfree bonds between the thin and exotic metals essential for the high-performance batteries used in electric vehicles, cell phones, and personal electronic products.

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Well-designed joints can be ultrasonically welded in less than a second. Ultrasonic welds create strong bonds that are nearly as strong as the parent material. The COVID-19 pandemic further highlights the value of ultrasonic welding in cutting, seaming, and joining non-woven fabrics and thin plastic films essential to infection control. This includes its role in the production of many types of personal protective equipment (PPE) and infection control products used by medical personnel and first responders. Examples of PPE include surgical masks, gowns, protective curtains, absorbent pads, bandages, bedding, and more. Interestingly, although ultrasonic welding is diverse in its applications, its core technology is quite similar. The basics The components of an ultrasonic welding system are a power supply, an actuator, and a stack. The power supply takes the line voltage (from the wall outlet) at a nominal 120-240V and transforms it into a highfrequency signal. It also provides the pre-programmed weld parameters necessary to operate the actuator and ultrasonic tooling (the stack), which work together to complete the welds. The ultrasonic stack connects to the actuator

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assembly. The stack has three parts: 1. The converter, which translates signals from the power supply into mechanical vibration (amplitude). 2. The booster, which fine-tunes (increases/decreases) the amplitude as needed for the plastics being welded. 3. The horn, which precisely transmits this vibration to the parts or surfaces being joined. The shape of the horn is extremely important. To weld efficiently, the face of this tool must match the profile of the rigid parts being joined or provide a sealing profile when the parts or components are being joined. For each application, the stack (converter, booster, and horn) work together to deliver the optimum level of amplitude to produce a consistent ultrasonic weld. In operation, the actuator lowers the stack onto the parts to be joined, compressing them. Vibration is delivered to the part surfaces by the tool at the bottom of the stack, or the horn. Vibratory energy at the interface of the plastic parts generates frictional heat that melts the plastic, which

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Fastening + Joining Branson ultrasonic welding technology from Emerson is used to cut and bond non-woven fabrics into a variety of sterile surgical drape kits, masks, gowns, and scrubs essential for personal protection and infection control.

Ultrasonic welding is widely used in the high-volume assembly of plastic parts because it: • Integrates easily with automated processes. Ultrasonic welding equipment is available in a wide range of configurations, from compact benchtop to freestanding units that can produce multiple parts in a single cycle. • Offers fast production cycles. Many ultrasonic welds are completed in a fraction of a second, enabling production at a greater rate than processes that rely on other joining methods (such as adhesives or mechanical fasteners). • Requires zero consumables. Ultrasonic welds are completed directly between the surfaces of the adjoining parts. This means no additional material, fasteners, or adhesives are required. • Is extremely energy efficient. Unlike heat-sealing or joining processes that rely on a continuously heated element, ultrasonic welders consume energy only during the weld cycle itself. Since tooling is never heated, there’s no cooling time required to switch ultrasonic equipment over for production changes. Simply swap out the tooling, update the programming, and begin production. • Enables sophisticated and secure data collection. For manufacturers that must validate product quality and ensure product traceability to meet medical, regulatory, or performance requirements, the latest ultrasonic welding systems offer extensive data collection capabilities.

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— under force from the actuator — compresses and bonds, producing a finished ultrasonic weld. Production efficiencies Assembling plastic parts, films, or non-wovens using ultrasonic welding requires some up-front investment, starting with the welder itself. Additionally, product-specific tooling is required to precisely hold the various plastic components in place as a part is welded. All of this is a one-time investment, which means that operators can manage assembly costs, amortizing a single investment over the entire production volume of the part. When the part or product design is finalized, weld tooling can be built and highvolume production can begin. The key to amortizing assembly method costs and realizing long-term assembly savings: first have a firm idea of what the annual production volume is going to be. History shows that those with production volumes ranging from tens of thousands to millions per year generally attain a significant financial benefit with an ultrasonic welding process. Non-wovens and infection control The low cost and utility of non-woven fabrics have made them essential in the global battle to prevent the spread of infection, including COVID-19. Disposable non-wovens provide an effective yet inexpensive barrier against micro-organisms and contamination, making them ideal for surgical protective garb.

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Similar to other plastics, nonwoven fabrics can be joined with ultrasonic welders, using highfrequency mechanical vibration, which is transmitted through tooling to heat and join thermoplastic material. Depending on the selection of weld parameters and tooling, the frictional heat generated by ultrasonics also offers the versatility to: • Cut or slit a large roll of nonwoven fabric into narrower strips (cut edges are simultaneously seamed and sealed by the heat). • Bond two pieces of non-woven fabric into the finished seam of a garment or a piece of protective gear, such as a surgical gown or mask. • “Quilt” multiple layers of nonwoven material into laminated absorbent products. Compared to adhesives, ultrasonic eliminates the cost of consumables, the time required for setup and drying, and the risk of exposure to chemical contaminants. Compared to sewing, ultrasonic offers benefits because it creates high-strength, high-integrity seams without the need for thread and without creating mechanical holes in the fabric, which can hold and conceal microorganisms or contaminants. Ultrasonic seams are ready for use as soon as they are produced.

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Why limiting fasteners can lead to better designs Michelle Froese • Editor

Imagine you’re an engineer with the freedom to create any design you’d like with only one catch: you can only use two types of fasteners. Would this limit or simplify your design? For Marisa Mudge, marketing manager with Mudge Fasteners, Inc. (a supply company owned by her father), the answer is simple: “The idea of designing with limited, standard parts is absolutely brilliant because of the significant time and cost-savings it, ultimately, provides,” she says. Although Mudge is not a design engineer, she’s worked fulltime at Mudge Fasteners for more than a decade (and much longer, if you add in the time she helped her dad at the company in her adolescence). So, she knows a thing or two about fasteners. When she met an engineer from Hewlett Packard on a plane one day — who is limited in his designs by the use of only two screws — Mudge was impressed by the company’s mandate. “One of the biggest problems companies face related to fasteners is lost parts. Typically, fasteners are the smallest part at a job site and minimal efforts are spent tracking this inventory… so the screws or bolts get dropped at construction sites, lost on manufacturing floors, or accidentally left in pockets,” she shares. “So, a project with only two standard fastener choices would have a real advantage.” A few lost fasteners may seem like a small problem, but replacement costs can add up quickly. “Some standard fasteners run in excess of a dollar or two apiece,” Mudge says she often gets calls from companies that suddenly need 200 or 300 additional parts after ordering 20,000 for a job. This means a lost advantage in bulk purchasing 86

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power. “Generally, these costs are significantly higher for custom fasteners.” What makes matters worse are the lead times. “Customized parts can take two or 20 weeks to replace, which can seriously affect project deadlines,” she says. “And most of the calls we get are not directly from the design engineers or project managers. Rather, the calls come from the workers out in the field who are under pressure to have a product manufactured or installed by a certain date. The concern is the workers may develop a workaround.” What Mudge means by “workaround” is the next best solution but, possibly, not the ideal fastener for the job. “This is why it’s extremely important to consider fasteners at the design stage of a project and plan for challenges during construction, such as lost parts,” she says. “It’s also why a DESIGN WORLD

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Simple is often best. Typically, design engineers can save costs and meet project deadlines by only using standard fasteners and limiting the type used for each application.

couple of standard fasteners per application would generally make life a lot easier.” There are additional reasons why pre-planning is important. For example, Mudge worked with one client who insisted on fasteners that would perfectly match the color of a project’s auditorium walls — and at a guaranteed cost. “In this case, we had to provide raw, non-customized fasteners because our vendor was unable to guarantee the paint required to match that exact color.” The reason for this was simple: the environment the fasteners would be exposed could affect the paint and color, so to guarantee it was impossible. “In such cases, the architectural aesthetics can really drive up the cost of fasteners,” she explains. The conditions fasteners are subject to, such as moisture or high heat, can also affect their reliability. “This is where standards come in, which can sometimes be an issue with custom fasteners,” says Mudge. “Standards organizations specify and test the properties of fasteners, but there are several different organizations and standards that should be adhered to depending on the application.”

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Marisa Mudge and her father, Paul, at the Mudge Fasteners headquarters in California.

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Going standard The advantages of designing applications with standard parts and limited fasteners:

• Minimizes problems with inventory management • Eliminates the risk of dead stock related to project design changes • Reduces procurement delays • Facilitates stock replenishment (and re-order points are simple to calculate) • Mitigates “stock out” occurrences because of a limited product range • Saves time and costs

with only two screws

For example, the Society of Automotive Engineers or SAE is primarily focused on safety regulations for the aerospace, automotive, and commercial-vehicle industries. The American Society of Mechanical Engineers or ASME provides manufacturers with guidelines and tolerances that their bolts must conform to. (View a list of the main standards organizations at mudgefasteners.com/ standards-organizations)

because, even as their

Typically, standards are categorized into:

“Hewlett Packard is at an advantage by allowing engineers to design

products change or improve, the company is never going to be stuck with dead inventory or 20,000 fasteners that they bought because procurement and design were not on the same page,” says Mudge.

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• Products – the different types and product gaging (ex. ASME B18.2.1)

• Materials and performance – specifications and strength (ex. ASTM A325)

• Testing – test equipment protocol and methods of testing (ex. NASM1312)

• Quality – fastener reliability (ex. ISO 9000) “Consensus standards offer many benefits that are not covered by nonstandard fasteners,” explains Mudge. This includes guidance and policies backed by significant research and expertise. “ Although an engineer can anticipate performance based on the material when using a custom fastener, the part is not required to meet any of the design

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specifications set forth by the consensus organizations, so there’s risk involved.”. Mudge recommends working with a vendor partner during the design phase of an application to identify standard parts and the ideal choice for an application. “Typically, fasteners are the least expensive component for a job and given little forethought. But this doesn’t mean they’re unimportant,” she says. “In fact, quite the opposite is true. These small components hold an entire application together — which is one reason standard fasteners that are reliable and readily available are often the ideal choice.” One other reason standard fasteners are ideal is to avoid unused inventory, which can happen as a product changes or evolves. “Hewlett Packard is at an advantage by allowing engineers to design with only two screws because, even as their products change or improve, the company is never going to be stuck with dead inventory or 20,000 fasteners that they bought because procurement and design were not on the same page,” says Mudge. “It’s a wise business decision.”

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The paint doctor: How D.L.P. Coatings got its start Michelle Froese • Editor

Treat others how you want to be treated. According to Patrick Murphy, VP of D.L.P. Coatings, Inc., a provider of quality painted fasteners, that is one of the key business lessons his dad taught him. His father, Richard “Dick” Murphy, opened D.L.P. in 1985. “My dad was originally a manufacturer’s rep in the fastener industry and then got a somewhat crazy idea to go out on his own and paint fasteners because he thought he could do it better than what was available at that time,” shares Patrick Murphy. “And, in many ways, he was right.” Murphy says the first shop his dad opened was about 5,000 square feet in Elk Grove Village, Illinois (about a 40-minute drive from downtown Chicago). Today, the company works in a 40,000 square-foot building. “Sadly, my dad passed away last year but this company was his life. He gave so much to it and worked hard to grow it to what it is today. In fact, his very first employee, Mark Duncan, still works for us some 35 years later.” Murphy joined the family business 12 years ago and hasn’t looked back since. “I somehow always knew that I’d work with my dad but first wanted time on my own, independently, to figure things out,” he says. “Then, shortly after I graduated from college with a marketing degree, the 2007-08 recession hit, and the job market was bleak.” Additionally, his father had some health concerns at the time, so it made sense that Murphy began learning the business alongside his dad. “I haven’t regretted a moment of the decision to join D.L.P Coatings. My dad was the best 90

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mentor you could ask for. He was very down-to-earth and supportive of those around him. And he absolutely loved the work.” Murphy’s dad built the business from a general fastener coating company to one that offers several added services, including waxing, assembly, packaging, and others. It also serves several industries such as window and door, residential and composite decking, truck and trailer, lighting, electrical, and automotive — including big companies such as Anderson Windows and General Electric. One unique service D.L.P. offers is a computer color matching system. This process uses a spectrophotometer to measure the exact intensity of color wavelengths. Then, a mathematical analysis of DESIGN WORLD

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t Patrick Murphy, VP of D.L.P. Coatings, with his son Grayson, and his dad, Dick Murphy.

the color sample and a formula for a targeted color match is created. “We do all of the color matching in-house and the process is so precise that it can be modified to fit varying color and lighting specifications,” explains Murphy. “It’s similar to going to Home Depot or Lowe’s to match the paint color for your walls, but for industrial parts and fasteners. So, for example, if a customer has a metal building with sheet metal in Hawaiian Blue, we’re able to match and make that exact color of blue at our facility to paint the fasteners — no matter the shade.” Murphy says D.L.P. offers exterior grade-paints that have been engineered with the company’s manufacturers, with proven UV, chemical, and chip and scratch DESIGN WORLD

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resistance. The paints are also environmentally friendly. “We have a lot of customers who have been with us for a long time and I credit that to my dad. He treated everyone in the same way… he was always fair and respectful. And I try to do the same. We’re not changing anything here. We’ve even kept the same paint and the same kind of paint systems. We’re only working to continually improve the process.” According to Murphy, one of the biggest challenges is that the company is typically considered a second or third-tier supplier, and one of the last considered during a project or for an assembly. “This means we’re typically the last to touch the part and by the time it hits our door, the order is already hot. www.fastenerengineering.com

The customer has been waiting for six or eight weeks, or longer.” The challenge is in, then, getting each part processed and painted as quickly as possible. Murphy encourages people to think of such details earlier in the design stage of a project. “The reality is that most people simply don’t think about the fastener color until late in the game,” he says. “But my dad often called himself the paint doctor and for good reason. He always said there wasn’t a problem we couldn’t solve or customer we couldn’t support at the company and we continue to stand by that.”

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How

ZAGO Manufacturing

has built its success on teamwork Michelle Froese • Editor

Zero regrets are something the owners of ZAGO Manufacturing, a global manufacturer of high-tech, custom sealing solutions and components, can attest to after more than 25 years of business. Husband and wife team, Harvey Rottenstrich and Gail Friedberg began the New Jersey-based company in 1993. “We’ve never once had second thoughts about starting or moving forward with ZAGO,” shares Friedberg. “Over the years, we’ve received inquiries from private equity firms and other companies that wanted to merge with us. But we’ve held firm and said no. We have a really good thing going here and we’re proud of what we’ve built.” The commitment to begin the manufacturing company first began with support from a small-business incubator program, NJIT Enterprise Development Center, which is part of the New Jersey Institute of Technology. “For a few years, the program provided us with office space at a reduced rate for rent, secretarial services, as well as space for assembly and production,” explains Friedberg. “But, perhaps, the most important things it gave us were resources and critical business advice.” At the time, Friedberg was a practicing corporate lawyer and was able to help with the development and legal requirements of opening a business. Rottenstrich is an electrical engineer who had experience working in the fastener industry, which was the initial inspiration for ZAGO Manufacturing. 92

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“My husband had worked for a company that did something similar to what we offer but felt he could do it just as well, if not better. So, essentially, he brought the engineering experience and I brought the legal support, and, between us, we also had a lot of business knowledge,” she says. “Sure, there were challenges, but we were about as prepared as we could be to start the company.” The name, ZAGO, was derived from each of the family member’s initials (the FriedbergRottenstrichs have three kids — one of whom currently works in the company’s factory). “As exciting as it was at first, it was also a lot like jumping off of a cliff,” adds Friedberg. “Starting a business certainly isn’t simple. But you have to just take the leap and push forward because it is frightening. You invest a lot of time, effort, money, and hope for the best. So, there are definitely nerves tied in with that.” DESIGN WORLD

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The wife and husband team behind ZAGO Manufacturing, Gail Friedberg and Harvey Rottenstrich.

The building of ZAGO was gradual and careful. After getting a foothold in the market, the next step was graduating from the incubator program. “After five years, we outgrew the incubator and actually graduated with an official plaque.” Friedberg says they then briefly rented another workspace until finding their current location in Newark, which allowed enough space to grow. “It basically started with just my husband and me, and a telephone, but we now have 22 employees, which is wonderful,” she says. “We’re proud of our team. And we’re very dedicated to growing through automation and robotics for the quality and precision of our products.” To this end, ZAGO does more than just produce customized DESIGN WORLD

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sealing fasteners and components. According to Rottenstrich, ZAGO sealing screws, bolts, and nuts are sustainable, corrosion-resistant, and inherently “green” solutions. Unlike traditional fasteners, ZAGO sealing fasteners are engineered with a rubber O-ring that when tightened, creates an air-tight, 360-degree seal. This hermetic seal effectively shields toxins from leaking in or out into the surroundings while protecting high-asset machinery and complex equipment. “The product was originally a military one and that’s still a major market for us,” explains Rottenstrich. “If you think of marine or aerospace environments, it’s critical these components withstand harsh pressure, temperatures, and environmental conditions — sealing www.fastenerengineering.com

out water or moisture, air, fuel, and dust or debris.” Today, ZAGO produces custom and standard sealing fasteners and switch boots for thousands of equipment manufacturers, including those in the automotive, energy generation and storage, robotics and drones, commercial lighting, electronics, enclosures, and medical device industries. “Some of these products are extremely delicate or tiny and their purpose is unlike a conventional fastener, which is designed to hold components together. Rather, these parts prevent elements from penetrating equipment, which would lead to malfunction,” he says. This is extremely important in medical devices, such as ventilators, for example. ZAGO has been deemed an essential manufacturer during the COVID-19 pandemic and is still operating. “We’ve always sold to the medical July 2020

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Fastening + Joining device industry but their needs have, understandably, grown at this time and we’re grateful to help out. For example, we were selling to Ventech, which is now partnering with GM to make ventilators,” says Friedberg. ZAGO is also determined to support and maintain its staff at this challenging time. “How we treat our team has always been significant to our company ethics,” she shares. “This is especially true right now and we’re doing everything possible to offer our staff full salaries, regardless of how many hours they put in because of split shifts or what have you. People’s needs don’t change because of the situation right now. If anything, they’re greater as they care for family and extended families.” Although the current pandemic is unique, Friedberg says she and her husband have typically used difficult times in the past as opportunities to reflect. “We’ve tried to use slower periods, such as during the recession, to review and improve our operations. Sometimes when you’re busy or constantly on the go, it’s tough to contemplate things or focus on possible changes or improvements,” she says. “So, slower times can also be important for future planning and growth.” That’s one quality Friedberg says has been critical to their success: “We understand that there’s always room for improvement. For instance, we encourage our employees to come to us with suggestions for improvements and we actually reward that, monetarily. If someone comes up with a great idea, we make sure they benefit from it. The worst reason to do something is because we’ve always done it that way.” Rottenstrich agrees. “I think for us, at least from my experience, a willingness to try new things and create…and, most importantly, to ensure there are good, supportive people around us has been the key to our success.” “Teamwork is everything,” adds Rottenstrich. “And we’re so fortunate to have employees that we consider a part of our extended family.”

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F a s t e n i n g

J o i n i n g

The how and why

behind the Fastener Training Institute Michelle Froese • Editor The Fastener Training Institute’s John Wachman (managing director) and Jo Morris (director of marketing) at an industry event last year.

What began nearly 50 years ago as a collaboration between fastener distributors to train new employees has since developed into an international organization for novice and advanced individuals working in the industry. Today, the Fastener Training Institute (FTI) provides a host of training programs by recognized industry experts on fastener products, standards, and specifications. The aim, according to FTI’s objective is “to enhance fastener use, reliability, and safety.” “The root of the fastener training Institute began in the early 70s with an industry group called the Los Angeles Fastener Association, or LAFA,” explains John Wachman, the current managing director of FTI. “Those who were a part of LAFA decided that, individually, no one had the bandwidth to train new employees but that collectively they could probably do a decent job. And so, began the first basic industry training classes.” Wachman, a 45-year veteran of the fastener industry — who also founded his own manufacturers’ rep agency in Arizona, Desert Distribution Sales, 96

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which he still runs today — was asked to join the board of LAFA in 2006 “Once on the board, I took part in the product training committee and within a couple of days was asked to serve as the chairperson for the full training committee, which I accepted, and that’s how FTI got its early start and how I became involved with training,” he says. FTI’s future was still developing, however. In 2009, LAFA merged with the Western Association of Fastener Distributors to form the Pacific-West Fastener Association, a western trade association for distributors DESIGN WORLD

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and suppliers. “Pac-West managed FTI for a while, but it was primarily a regional association and the demand for training classes began to grow considerably.” To support the education needs nationally the PacWest Board of Directors decided to formally launch FTI. “FTI became a standalone, registered 501(c)(6) non-profit in 2014 and that’s when it grew from a regional association to a national training platform,” says Wachman. “The classes grew from very basic, which we still offer, to highly advanced.” Today, Desert Distribution manages the Fastener Training Institute under contract with FTI’s board of directors (BOD). The BOD consists of fastener industry producers and distributors from throughout the country, with backgrounds and experience wellsuited to guide FTI’s future. “What’s interesting is that much of our mandate is similar to what it was when FTI started with LA FFA,” says Jo Morris, the FTI director of marketing. “We exist to serve the fastener industry and we continually train new employees.” What has changed to some extent, however, are the needs of the fastener industry. “This is why we’re always asking for feedback so we can best serve the industry with useful and timely training,” she adds. Here are a couple of examples of the changing fastener landscape and how FTI addresses it in their current training curriculum. Maturation. One trend in fasteners that Wachman and Morris have noted is the effects of an aging industry. “There’s a lot of people retiring but without an immediate successor

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who’s been in the industry, climbed the ladder, and gained the experience necessary to take over the role,” says Wachman. “There’s somewhat of a gap in talent here and this means there’s a risk that the tribal or historical knowledge could be lost.” “This is why we offer such a broad product base of training options and only from instructors who’ve worked with fasteners and are considered industry experts,” explains Morris. “Where fastener companies were typically family-run businesses, today that’s changing.” The lack of mid to seniormanagement employees who have “grown-up” in the fastener industry has led to an influx of new employees, who require significant training. Although these new employees typically offer management experience from other industries, the in-depth insight that’s specific to fasteners is often lacking. For FTI, this has led to two challenges: teaching decades of “historical knowledge” in a short time period and securing industry retention rates. “We’re supporting a lot of new hires. By providing them with proper training and a sense of community, our goal is to ensure these individuals gain the confidence and skills required to stay in the industry and succeed,” says Morris. Troubleshooting. Much like any industry, fasteners do experience failures. According to Wachman, however, it’s rarely the result of faulty components. To this end, one of the most significant advanced engineering classes FTI currently offers is on fastener failures. The aim is to increase the reliability and safety of the industry

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and the professionals working in it. “I’m certainly not implying companies never make faulty fasteners. It happens,” says Wachman. “But the primary reason for joint failures is rarely a defective fastener. It’s usually because a person either specified the wrong fasteners or improperly installed them.” “Typically, when there’s an application failure the fastener gets blamed,” agrees Morris. “But as John mentioned, most fastenerrelated problems relate to misuse either from improper selection, specification, or installation. So, it’s extremely important that FTI offers advanced engineering classes focused on fastener selection and proper installation to prevent unnecessary faults and failures.” One of the ways FTI ensures successful training is by only offering classes with instructors that are recognized industry experts. “Our instructors are full-time, industry engineers with decades of experience in the industry — they’re not academics,” says Wachman. “They’ve worked 20, 30, or 40 years on the job. So, when teaching a class, the instructors are offering the class content as well as years of reallife career experience.” Wachman adds: “It’s so great when we hear we’ve impacted the work and knowledge-base of newcomers and industry veterans. That’s what we’re here for.” Check out fastenertraining.org to learn about FTI’s current virtual classes and webinars.

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Fastener Engineering Products

Surface-friendly wave springs Rotor Clip rotorclip.com Engineers choosing springs for bearings typically prefer ones with a high axial load to reduce vibration and noise — and prolong bearing life. However, standard single-turn wave springs with a gap have sharp corners at the cut-off area of the spring ends. These corners can scratch the surface of the bearing and mating parts when the waveform shows a steep incline, depending on the load specification. This debris can lead to failure of the bearing and an entire application. Rotor Clip’s patented design solves this problem by flattening the ends of the spring so they avoid causing excessive wear that can damage an application. As with all of Rotor Clip’s wave spring designs, there are no tooling costs for custom designs with this end feature.

A U-handle with power-switching function JW Winco jwwinco.com JW Winco has added electrical features to mechanical components to create the GN 422 U-handle with power-switching functions. The electrical push-button is made of high-quality stainless steel and equipped with a special twocolor LED, which switches between red and green depending on the polarity. This indicates the current production machine status. For mounting, including professional electrical installation, the U-handles come supplied with either a plug connector or cable. The cable pass-through is covered, with the cable running out the back of the housing to be out of the user’s sight. Depending on the application, the U-handle can be ordered in black or silver with one or two LED buttons.

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Fastener Engineering Products

A thermally conductive epoxy sealant Master Bond masterbond.com Master Bond EP62-1AO is a two-part epoxy adhesive and sealant with an extremely long working life — ranging from 12 to 14 hours an at ambient temperature for a 100-gram mass. This is ideal for bonding and sealing large or intricate parts that may require ample time for mixing and applying. EP62-1AO is electrically insulating and thermally conductive with a thermal conductivity value of nine or 10 BTU•in/(ft2•hr•°F), or 1.30-1.44 W/(m•K). The adhesive can withstand a wide range of acids, bases, and solvents. The viscosity of the mixed compound offers a thixotropic paste consistency. The material has a high-strength profile with a tensile modulus of 600,000 to 650,000 psi and a tensile strength of 5,000 to 6,000 psi. The service temperature range is -60° to +450° F.

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Fastener Engineering Products

Advanced parts counter Advanced Poly-Packaging, Inc. https://ecom.advancedpoly.com Whether bagging fasteners, hardware, or components, Advanced PolyPackaging’s Ultra-Count Series counters provide the flexibility and speed to get the job done quickly and accurately. The counters offer thick-coated, stainless-steel bowls, which provide a long life (even when running abrasive or sharp parts) and easier filling capabilities. A programmable, self-training photo-eye count is available for only those parts that are within the set range of acceptance. Additionally, the reliable and heavy framework offers a “two-cushion” suspension for smooth and accurate parts flow. An integrated conveyor system automatically adjusts the speed for maximum production.

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Keystone Electronics’ new series of metric threaded, titanium socket-head cap screws are manufactured from C-276, Grade 2 Titanium, fully meeting DIN912 specifications. These screws are ideal for use in corrosive environments involving seawater, acids, chemicals, petroleum, biomedical, or power-generation operations. The socket-head cap titanium screws have a high strength-to-weight ratio and are about 40% lighter than steel screws. Designed with a knurled head featuring a hexagonal drive socket, the screws are available in M3, M4, M5, and M6 threads and lengths of 10, 16, 20, 30, and 40mm.

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Adjustable levers have proven to be ideal wherever parts have to be clamped in a confined space or with a particular lever position. The series WN 306 with plastic lever body and GN 306 with zinc die-cast lever body are available with various special-tipped threaded studs. The brass and plastic tips help to avoid damage to the workpiece being clamped whereupon the hardened tip provides an oval point-shaped pressure point. The swivel thrust pad can easily be clipped on and taken off.

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