In the drive to reduce weight, automotive companies and their suppliers are continually targeting any opportunity available – with many moving from metals to composites. However, although the transition to composites has been embraced, bigHead Bonding Fasteners Ltd says that there are plenty of examples that the transition to composite fastener solutions has been slower or even overlooked.
bigHead says that it has come across a number of examples of designs transitioning from metal to composite materials but still using traditional fasteners designed for metal applications. These traditional fasteners require design adaptations of the composite that increase weight and material.
SMC vehicle floor pan with structural reinforcement material built up around traditional fixing solution
“Composite material is often bulked-up just to hold a fastener securely in position,” explains Matthew Stevens, managing director at bigHead. “This bulked-up material increases the volume of material, takes up space and can restrict design options. It is also unsightly.”
By contrast a bigHead fastener, which is precisely designed to be embedded in composite materials, does not require the material to be reinforced at all. The 1.2mm thin head on a bigHead can be embedded in most composite substrates without any additional material. The wide perforated head ensures any load is evenly and securely distributed into the composite material and does not compromise design. Furthermore bigHead mentions that its fasteners are 66% lighter than traditional bolts and that is not including the weight saving from not having bulked-up composite material.
Like the traditional fasteners often in use, the bigHead fasteners can also be set in the mould tool to be embedded during the mould process, avoiding any need for secondary operations. The wide range of bigHead designs, with different head shapes and sizes, also means that designers do not need to compromise their designs to accommodate a secure mechanical fastener.
Having spent a decade in the fastener industry experiencing every facet – from steel mills, fastener manufacturers, wholesalers, distributors, as well as machinery builders and plating + coating companies, Claire has developed an in-depth knowledge of all things fasteners.
Alongside visiting numerous companies, exhibitions and conferences around the world, Claire has also interviewed high profile figures – focusing on key topics impacting the sector and making sure readers stay up to date with the latest developments within the industry.
