Engineered Fastening Fastening Solutions for Plastics

Inserts Dodge inserts for plastics are the most widely recognized and highly regarded products in the fastening market. Since the 1950’s, Dodge has been identified as the leader in its industry which can largely be attributed to its focus on providing high quality products. Plastic Parts, Metal Threads Threaded Inserts Dodge inserts are designed to provide the high performance strength values of molded-in inserts while retaining all of the economical advantages of insert installation after molding. Compression Limiters Dodge non-threaded bushings expand the Dodge offering and are custom designed...

The test data included in this catalogue should be considered as average values for the general families of plastics indicated. Critical application requirements may necessitate further specific testing. As a result of continuous design improvement, Dodge products are subject to modification. Current technical data and drawings are available upon request.

Design Guidelines 1. Plastic Overview The two main categories of plastics where threaded inserts are used: Material Dodge inserts are traditionally made from 360 brass which falls under the designation UNS C36000 ½ hard free-cutting brass. The CDA specification is C360, ½ hard per ASTM B-16. a. Thermoset Plastics Thermoset plastics cannot be re-melted using heat or pressure once they are formed into their desired shape, These plastics tend to be hard and brittle. Since they will not re-melt, inserts installed by heat or ultrasonic can’t be used in these materials. Recommended insert types include:...

Design Guidelines Straight vs. Tapered Holes - Straight hole preparation allows for a taper that should not exceed a 1 degree included angle. Tapered holes require an 8 degree included angle. Tapering permits easy release of the core pin, aids in insert alignment, which in turn reduces installation time. » Straight Knurls Effective in applications focused on high rotational strength. » Multiple Knurls It is common practice to utilize more than one knurl style and direction on the same part to reach the most optimum combination of rotational and torque resistance. d. Flanges In certain applications,...

Design Guidelines d. Compression Limiters Considerations a. Heat Installation Heat installation involves positioning the insert into the molded or drilled hole. A heated tip is then inserted into the inside diameter of the threaded insert. Localized melting begins to take place and with the downward pressure, the insert begins to install. Plastic flows into the varying undercuts and knurls. Strength – The head of the bolt being used in the assembly must seat against the compression limiter to avoid potential failure due to plastic creep. Mating Components – The mating component must also withstand...

Design Guidelines c2. Spred-Lok Inserts Economical and easy to install. Designed for non-critical applications. Insert is pressed into a straight prepared hole, expansion of the insert is accomplished through the installation of the mating fastener. Mating bolt should be long enough to extend at least two full threads beyond the insert length to ensure insert retention. Standard Expansion Economical and easy to install. Expansion inserts feature a two piece design consisting of a threaded insert and a captivated spreader plate. The insert is installed into a blind, straight hole and the spreader...

Applications Dodge Inserts and Compression Limiters are widely used in critical applications in the automotive, electronics, medical, transportation and general industrial markets. Threaded Inserts for Plastic Components In the overhead aircraft interiors, brass inserts are used to strengthen and maintain joint integrity in brittle and soft material extending service life and value. Air Intake Manifold Using the TaperTuff® and Ultrasert® in the intake manifold allows the OEM to create strong reusable threads that eliminated cracking from bolt load. Grab Handle Using Compression Limiters eliminates...

Applications Industrial Appliance Fan Module Manufacturers of fan modules around the world depend upon Dodge Ultrasert® brass inserts for reliability and performance. Power Tool Housing Power tool manufacturers count on the Dodge Ultrasert® to provide the superior joint strength, vibration proof properties and high serviceability required of their products. Pump Housing Multiple Ultrasert® inserts are used in pump assemblies to provide high shear, tensile and torque necessary to handle the load of the fluctuating stresses in the application. Engine and Component Assembly In the high vibration...

Dodge Capabilities Product Development » Our Technical Center offers review of your application, product evaluation, analysis and recommendations to help reduce your assembly costs » Development support includes conceptual ideas, preliminary designs and drawings » Engineering prototypes and pre-production sampling resources available Quality » ISO/TS 16949: 2009 certified » Lot control ensures product traceability » Statistically controlled manufacturing processes » PPAP, IMDS, Material Certifications Sales & Applications Engineers » Strategically located throughout North America » Offer expertise...

Troubleshooting Guide PROBLEM Potential Solutions Insufficient Insert insert Insert Excessive Excessive Plastic rises above strength not Excessive flash flash boss Welder Insert top surface (pull-out, completely installation on top under bulges or overloads damaged after top rotation) seated time surface insert cracks (cuts out)* (deformed) installation Increase hole diameter Increase hole depth Increase boss diameter Decrease hole diameter Verify plastic melt Incorrect fixture design Countersink/Counterbore hole Increase amplitude* Increase pressure Increase weldtime Decrease downspeed Increase...

A fluted brass insert designed for ultrasonic or heat installation into thermoplastics. INCH INSERT SPECIFICATIONS Vertical flutes and horizontal fins provide superior assembly strength Tapered design assures rapid and accurate alignment prior to installation Flute and fin design provide a chip-free environment HOLE SIZE RECOMMENDATIONS Min. Boss Dia 8˚ D Min. Depth = Insert Length Plus .030 Inch (0.77mm) Thread Size Part Number Minimum Boss Diameter METRIC INSERT SPECIFICATIONS Thread Size Part Number HOLE SIZE RECOMMENDATIONS Diameter Minimum Boss Diameter