JOINERY

IN DIFFERENT MATERIALS

AR- BUILDING CONSTRUCTION
A/PROF. SMRITI SARASWAT
WOOD
METAL
PLASTIC

Butt Joint
Typically made by gluing an
end to an adjoining flat
surface.

An easy but often weak
technique

Biscuit / Plate Joint
A butt joint that is reinforced
with football- or lozenge-
shaped wooden "biscuits."
Biscuits are usually made from
compressed wood, frequently
birch wood.
When the biscuit comes into
contact with glue in the biscuit
slot, it swells thus creating a
tighter joint.
Dado Joint
A joint where one piece is
grooved to receive the piece
which forms the other part of
the joint.

Dado (definition)
o A groove which is cut across the
grain to receive the butt end or
edge of a second piece.
Dovetail Joint
Joining two boards in which alternating
slots (or tails) and protrusions (or pins),
each resembling in shape the v-shaped
outline of a bird's tail, are snugly fitted
together, thus increasing the gluing area.
Produces a joint that, even without glue,
can be difficult to pull apart.
Regarded as one of the strongest and most
reliable forms of wood joinery.
Lap Joint
A joint where one piece of
wood is crossed over another.
Miter Joint
The woodworking joint created
when two boards are cut at an
angle to one another.

The most common miter joint is the
45-degree miter such as the cuts
used to build square or rectangular
picture frames.
Mortise-and-Tenon Joint
A joinery technique where the cut end (tenon) from one board
fits into the matching opening (mortise) of another.

Mortise (definition)
o An opening chiseled, drilled or routed into a board to
receive the end of an intersecting board.
o The opening or socket that receives the tenon in the classic
woodworker's mortise-and-tenon joint.
o The female part of a mortise-and-tenon joint.

Tenon (definition)
o The end of a board, cut to a specific size and shape, that is
inserted into the mortise, or opening, in a second board.
o The male part of a mortise-and-tenon joint.
Rabbet Joint
A joinery technique where an L
groove across the end of the
edge of one piece of wood fits
into a edge or end of another
board with an L groove.

Rabbet (definition)
o A rectangular, stepped recess cut
along the edge of a section of wood.
(May be used as a verb or noun.)
Scarf Joint
A joinery technique where
two wedge-shaped pieces
have been cut to correspond
to one another.

Finger Joint
A joinery technique used mostly in
industry where small fingers are
cut into corresponding pieces that
will be joined together.

Finger joints are used to making
wide boards, in extending the
length of dimensional lumber, and
in laminated construction.
Key (or Biscuit)
o A small, flat lozenge-shaped dowel for
edge or corner-jointing. Wood biscuits
are fitted into slots that are created with
a biscuit jointer.
Dowel pin
o Pegs of wood that fit into two matching
holes to strengthen a joint.
Spline
o A thin piece of wood that fits in the
mating grooves cut into two pieces of
wood.
Joinery Reinforcements
Wood Fasteners
What fastener is best to use?
There are a few questions you need ask to determine which type of
fastener you need to use.
o What materials need to be joined? Wood, metal and masonry all require
different fasteners.
o What is the thickness of the material to be joined? For a secure connection,
the fastener must be the correct length.
o What weight or strength requirements are there? From framing a house to
hanging a picture, there's a fastener for the job.
o How permanent will the connection be? If the work will be disassembled at
some point, use a screw.
o Will the work be indoors or outdoors? There are specific fasteners for both
types of applications.
Nails

The first versions were heat-forged.
When machinery entered the picture,
they were cut from sheets of metal.

Today, most nails are drawn and cut
from rolls of wire.
Nail Size
Nails are sold by weight or length.

Wood nails are measured, or sized, according to
length.
o This is expressed by the letter "d" (called penny). The
symbol is English, signifying a pound in weight, related
to the weight in pounds of 1000 nails.
o Sizes run from 2d (2-penny/1" long) to 60d.

Nails generally are 1" to 6" in length, usually getting
thicker as they get longer.

Nails larger than 6" are sometimes called spikes.
Nail Styles
Nail points vary, but the four-sided diamond
point is the standard point found on most
nails.

Nail heads also vary.
o Smaller heads can be driven in and painted
over.
o Large framing nails have corrugated heads to
reduce the danger of a hammer slipping and
causing injury or damage.

Regular wood nails are often referred to as
wire nails.
Common Nail
o Thick, heavy-duty, general-purpose nail.

o Large, flat head for performing rough work such as construction
framing.
Box Nail
o Short, thin shaped nail with a blunt tip.

o Used to fasten smaller stock when common nails are too large.
Finishing Nail
o Small nail with cupped head for fastening trim when nail heads should
not show.

o Can be countersunk with a nailset, then filled over.
Brad
o Smaller version of the finishing nail up to about 1" long.

o Used for detail work such as attaching molding or trim.
Casing Nail
o Similar to finishing nail, but thicker and heavier.

o Used to attach case molding or rough trim where strength and
concealment are required.
Tack
o Very short nail with relatively large head and very sharp point.

o Used to fasten upholstery or carpet or to perform other light fastening
jobs.
Upholstery Tacks
o Short nails with ornamental or colored heads.

o Used for attaching upholstery where fasteners will show.
Screws
For fastening, screws are stronger than
nails.

They can be removed with less damage
to the material (especially wood) than
nails.

When using with wood, best practice is
to pre-drill a pilot hole to guide the
screw into position.
Screw Slot Types
Slotted
o Conventional single-groove screwhead.
o Applied with a flathead screwdriver.
Phillips
o Cross-slotted screwheads with U or V-
Shaped slots of uniform width.
o Driven with a Phillips screwdriver.
Torx
o Require special drivers with six point heads.
o Commonly used in electronics, metal or
automotive applications.
Screw Head & Thread
Types
Head Types
o Oval
Lower portion is countersunk and top is rounded.
Easier to remove & better looking than flathead screws.
o Round
Used where the fastened piece is too thin to permit countersinking.
Also used on parts that may require a washer.
o Flat
Used in applications where the head needs to be flush with the
surface.
Slotted and Phillips type are available.
Thread Styles
o Fine-thread
Work best for hardwoods.
o Coarse-thread
Intended for soft woods.
Wood Glues & Adhesives
By definition, glue is made from animal byproducts such
as skins and bones.
An adhesive is any product that joins materials
together.
Today, the words "glue" and "adhesive" have become
interchangeable.
Natural Glues are made from animal byproducts (hide
glue and casein) or plant sources (paste, cellulose and
rubber).
Synthetic Adhesives include polyvinyl acetate (PVA),
aliphatic resin, contact cement, hot melt, and
polyurethane.
Whether natural or synthetic, the bond is formed as the
liquid dries and hardens.
Adhesives are often used in conjunction with fasteners
to strengthen wood joints.
Animal Glues
o Used mostly for furniture making and woodworking.

o They are easy to work with, but less resistant to heat or cold.
Hide glue
Made from bones, hoofs and skin from animals and fish.
Dry form is mixed and heated (in a glue pot) into a
gelatinous mixture that is applied with brush.
Casein
Made from milk, powdered and reformulated with water.
Creates a waterproof bond.
White Glue (polyvinyl acetate)
o For wood, engineered wood, paper,
crafts and simple projects.
o Most commonly available in plastic
squeeze bottles.
o Begins to set within one hour, dries
clear.
o Has easy clean up, doesn't stain,
nontoxic, nonflammable.
o Is not waterproof.
o Requires work to be clamped for best
results.
Yellow or Carpenters Glue (aliphatic
resin)
o For woodworking.
o "Refined" version of PVA.
o Packaged in squeeze bottles.
o Varieties typically come in yellow or
brown.
o Begins to set within 15 minutes.
o Water-resistant nontoxic,
nonflammable.
o More resistant to temperature and
water than white glue.
o Work needs to be clamped for best
results.
o Used for indoor and outdoor
applications.
Contact Cement
o For bonding wood veneer and plastic
laminates to countertops.
o Water-resistant.
o Applied to both surfaces needing to
be bonded.
o After a designated curing time, the two
work pieces are put together.
o Forms an instant bond, leaving no
margin for error.
o Water-based versions are
nonflammable.
Hot Melt
o For crafts, general projects and
repair.
o Requires an electric glue gun.
o Adhesive is a 2-4" glue stick that is
inserted into the gun. Heat converts
solid to liquid for application.
o Begins to set in about a minute as it
cools and solidifies.
o Fills gaps for good adhesion.
Polyurethane
o For woodworking.

o Synthetic plastic-based material.

o Requires moistening of one or both
sides of the materials to be joined.

o Creates a strong bond.

o Can be difficult to clean up.
Fasteners
Metal assemblies are often held
together with fasteners, hardware
devices that mechanically join or affix
two or more objects together.
Assembling with most types of
fasteners allows components to be
repeatedly assembled and
disassembled.
This is important where a product is
expected to undergo modifications,
repairs, or where it may provide
access into an assembly.
Bolts
Threaded shafts that use a threaded nut
to fasten metal together.
Bolts are sized by length and thread.
Bolts are stronger than screws.
Bolts are classified by the type
of head.
o Stove bolts and machine screws
(actually bolts) are turned with a
screwdriver.
o Hexagonal- and square-head bolts
are held in place with a wrench while
the nut is turned to tighten.
Types of Bolts
o Carriage bolt
Smooth round head & course thread that starts part
way down the shaft.
Usually used to attach a wooden part to metal.
o Machine bolt
Hexagonal head & only partially threaded.
Used for precision attachment using threads to
secure materials together.
o Tap bolt
Similar to a machine bolt but the whole body is
threaded.
o Stove bolt
Round or flat head with course thread along the
whole body.
General purpose fastener used when precision fit is
not necessary.
o Stud bolt
No head and threaded on both ends.
One end is driven into material & the other end is left
exposed so that other parts can be fastened to it.
Types of Machine
Screws
o Machine & cap screws
Come with a variety of head & thread
types.
Used for precision fit into thread holes in
metal.
o Setscrew
Made with square heads or no heads.
Typically used for safety reasons to hold
a sleeve, collar or gear on a shaft to
prevent relative motion.
o Thumbscrews
Has one or two wings or a knurled head.
Used where a screw must be turned by
hand using the thumb and a finger.
Sheet Metal Screws
o Short thick screws that are self-
threading (cut or form their own
threads as driven into soft metals).
o Used in the economical assembly
of sheet metal.
o Threaded all the way down the
shank.
o Come in a variety of head types
depending on application.
Lag Screw
o Bolt is a bolt head with a screw body.
o Has either a square or hexagonal head.
o Used in fastening where maximum holding power is needed (i.e.-
holding a vice to to a work bench).
Nuts
o Type of hardware fastener with a threaded
hole.
o Usually hexagonal to permit tightening with a
wrench but may also be square, knurled,
winged or otherwise shaped.
o Along with a bolt, nuts are designed to capture
and fasten objects together.
Type of Nuts
o Machine screw nut (Hex nut)
Square or hexagonal shaped with fine or course
thread.
o Jam nut (Lock nut)
Thinner than an ordinary nut.
Used as a lock to keep another nut from
loosening.
o Castle nut
Has slots cut into the top of the nut that extend
upward making it look like a castle.
A hex nut with a slightly reduced slotted
cylindrical section on one end.
Used with a cotter pin to prevent loosening.
o Wing nut
A nut with two thin flat wings.
Used in place of a regular nut and can be turned
with the thumb and forefinger.
Washers
o Placed under the bolt head or the nut for a
firmer fasten.
o Designed to protect the surface under a bolt
or nut.
o Used to spread load of a mechanical
connection out over a greater area.
Type of Washers
o Plain washers
Circular, small flat piece to widen the
bearing surface of a bolt head or nut.
Measured by the diameter of the bolt
that fits into it.
o Lock washer
Used to lock a nut or screw in place, prevent it
from moving from vibrations.
o Helical spring - looks like a coil from a
spring that tightens when applied to
prevent movement.
o Toothed has teeth that wedge into
bearing surface when applied to prevent
movement.
Pins
o Used to hold mechanical parts together
or limit travel of moving parts.
o Cotter pin
Made of soft wire.
Placed through a hole in a bolt behind a
castle nut to prevent the nut from turning.
o Tapered pin
Used to hold a collar or pulley against a
shaft.
o Roll pins
Made from sheet steel that is rolled into a
tube.
Driven into holes slightly larger than a
standard hole size so they grip tightly
when pounded in.
Keys
o Used to keep pulleys and gears from moving on
shafts.
o Half the key fits into the keyway (a slot on the
shaft), the other half fits into a slot that is on the
pulley or gear.
o Square key
Most commonly used.
o Gib-head key
Toothed key that is useful when you need to
remove the key from one side of the pulley or gear.
Can be removed with a wedge.
o Woodruff key
Semicircular in shape and fits a matching
semicircular pocket in the shaft.
Key becomes locked in position and cannot be
knocked loose due to vibration.
METALS
Joining Metal
o As with wood, there are many ways of joining metal
permanently.
o The method used will depend on the function of the product, the
strength needed and the quality of the product.
o There are several ways of joining metal permanently.
Riveting
Soldering and brazing
Welding
o The later two of these techniques rely upon heat.
With soldering and brazing, the two metals are joined by melting a
second metal between them.
With welding, the two metals are melted and fused together.
Rivets
o Metal pins that look like bolts with no threads.
o Used to hold pieces together permanently.
o Used when fastening metals together that are not
easily welded, or where welding is not practical.
Rivet Characteristics
o May be either solid or tubular.
o Made from different materials such as
soft steel, aluminum, copper, and brass.
o Come with a variety of different shapes
and heads.
o For application, rivets are placed in
holes, pre-drilled in materials and
fastened together.
o With solid rivets, the headless head is
pounded to form a head.
o Hollow rivets are clinched at the
headless end with a special riveting
tool.
Spot Welding
o Form of resistance welding done with a spot welder.
o High current at a low voltage passes through a spot on two
pieces of metal (usually sheet metal) for a short period of time.
o Resistance to the flow of current through the metal at the spot causes
heat, which melts the metal and makes a spot weld.
o Most frequently used to weld metal joints but sometimes used to
weld sheet metal to small diameter rods or small flat bars.
Soldering
o Process of fastening two metals together with solder,
a nonferrous metal that has a lower melting point
than the parts being joined.
o Parts being joined are heated until the solder, when
brought into contact with them, melts and flows
between the surfaces.
o When the solder solidifies, it adheres (sticks) tightly
and forms a strong bond between the two surfaces.
Soft Soldering
o Occurs at temperatures below 800
degrees Fahrenheit.
o For general work, a solder called rosin
core 60-40 (60% tin, 40% lead) is
often used.
o Solder often comes in a coil of wire
1/16 in diameter but can come in
other pre-cut shapes, sizes, and forms.
o Heat for soft soldering is applied using
soldering gun or a soldering copper.
Hard Soldering
o If solder melts above 800 degrees Fahrenheit,
it is called hard soldering.
o Used where a strong joint is needed or where
the parts will be used in greater heat than the
melting point of soft solder.
o The most widely used hard solders are silver
alloy solders that come in ribbons, sheets,
wire, or pre-cut pieces of various shapes and
sizes.
o Often used in jewelry and art metalwork for
joining copper, silver, and gold.
o Heat for hard soldering is applied directly with
the flame of a torch.
Brazing
o Hard soldering processing where the filler material
flows into the joints using capillary action (the
natural tendency of a liquid to be drawn in between
two close fitting surfaces).
o Filler material used is brazing rods (60% copper, 40%
zinc).
Adhesive Bonding of Metals
o Process of fastening parts of metal products
together permanently with non-metallic materials.
o Often used as an alternative to mechanical
fasteners.
o When using adhesives, the entire joint must be given
even more consideration than when using
mechanical fasteners.
o Unlike a bolt or rivet, an adhesive's properties may
change depending on where it is used.
o Light-gauge materials are often good candidates
for adhesive bonding.
Advantages of Using
Adhesives to Join
Metals
o Many adhesives easily join dissimilar materials if proper
surface treatments are used.
o Adhesively joined structures and products are inherently
smooth.
o Exposed surfaces are not defaced, and contours are not
disturbed as with other types of fastening systems.
o This is important both to function and appearance.
o Adhesives are sometimes used with mechanical
fasteners for sealing flange joints or holding the parts
together while the bond forms.
o Thin or fragile metal parts can be bonded. Adhesives do
not usually impose heavy loads on materials, such as in
riveting, or localized heating, such as in soldering or
welding.
Cyanoacrylates
(superglue)
o Adhesives developed for production situations
requiring instant bonds and immediate handling
strength, particularly when bonding rubber, metals
and plastics.
o These adhesives are especially well-suited for trim
attachment and light assembly.
o Cure through reaction with moisture held on the
surface to be bonded.
o Good environmental resistance; therefore, they offer
excellent resistance to weathering and aging.
Epoxies
o Synthetic adhesive made of two components, a liquid resin and
the hardener to convert the liquid resin into a solid.
o Create superior bonds for a wide variety of materials including
metals, rubber, and plastics.
o Widely used in the automotive industry.
o Many cars and light- and heavy-duty trucks feature body panels
bonded with epoxy adhesives.
o Excellent environmental and chemical resistance.
o They resist the effects of dilute acids, alkalis, solvents, greases, oils,
moisture, sunlight and weathering.
o Flexible cure rates.
o Allow great versatility in formulation since amount of hardener can be
adjusted to increase work time or decrease set time.
o Low shrinkage and good creep properties.
Urethanes
o Primerless adhesive that is ideal for prepared metals, rubber and fiber
reinforced plastics.
o Create strong flexible bonds that bring excellent structural integrity to
assemblies made of plastic, metal, foams and elastomers.
Anaerobics
o Specialty adhesives designed to cure on metals
in the absence of oxygen.
o Primarily used to anchor threaded joints and
shafts against breaking free due to vibration.
o Can eliminate the need for lock washers and
press fitted metal joints.
o Often known as "locking compounds.
o Based on synthetic acrylic resins.
PLASTICS
Snap-Fits
Molded-in pieces in a plastic
assembly that are designed to form a
mechanical joint system where part-
to-part attachment is accomplished
with locating and locking features to
connect components together.
Provide for the economical and rapid
assembly of plastic parts.
Types of Snap Fits
Snap-fits are used to assemble
parts of all shapes and sizes.

A snap fit with a tapered finger
provides more uniform stress
distribution and can be used over
and over again.

There are three types of snap-fits:
cantilever, torsion, and annular.
Use of Snap-Fits
Snap-fits are often used for high-volume production.
In many products, snap-fits are designed for one-time
assembly without any provision for nondestructive
disassembly.
o For example, snap-fit designs, such as those used in the plastic
shell of small kitchen appliance or a childs toy, are not designed
to be taken apart without destroying the product.
Where servicing is anticipated, snap-fits can be designed
that allow for release of the assembly with an appropriate
tool.
o For example, snap-fit designs, such as those used in battery
compartment covers for calculators and radios, are designed for
easy release and re-assembly over hundreds or even thousands
of cycles.
Cantilever Snap-Fit
Consists of a protrusion (some type of
bead or hook) at one end of the beam
and a structural support at the other end.

Most common type of snap-fit used for
plastic assembly.

Commonly used in applications such as
toys or battery compartment doors.

Most cantilever snap-fits are usually a
one-time use but some designs can be
used more than once.
Cantilever Snap-Fit (continued)
Snap fits that are intended for one time
use have a sharp edge, or tang, that
holds the part in place.
Snaps intended for limited use will have a
rounded tang to allow the snap feature to
be pulled off yet still have holding ability.
o With this type of snap fit, the plastic
does not experience a lot strain, so
multiple flexes are possible without
damaging the plastic beam.
o It also has a built-in stop, so the
beam cannot be flexed too much
and damaged.

Torsion Snap-Fit
Spring-loaded lever that snaps into place when the
mating part is pressed into place.
The torsion snap can be released by pressing down on
the lever.
This design can be used for frequently assembled and
disassembled parts, or to provide constant pressure to
the assembly.
The complexity of this type of snap-fit, prevents it from
being widely used in industry.
As its name implies, the torsion snap-fit relies for its
spring effect on twisting rather than flexing like the
other types.
It is less common than cantilever or annular snap-fits
but it is particularly useful when you want to be able to
release the catch easily and often.
o For example, a torsion snap fit can be a good
way of fastening a hinged lid on a box or
container.
Annular Snap-Fit
This type of snap fit is best for assembling cylindrical or ring-shaped
joints.
o Classic examples include ballpoint pens with snap-on caps, the child-resistant caps on
medicine bottles, and cottage cheese container lids.
Generally stronger, but needs greater assembly force than their
cantilevered counterparts.
Annular snap-fits are basically interference rings. There is a smaller-
diameter male component (plug) which has a bump or ridge feature
around its circumference. The ridge diameter of the plug is slightly
larger than the inside diameter of its mating tube-shaped female hub.
Benefits of Snap-Fits
An integral element of the plastic part no other
components are needed.
Can replace screws, nuts, and washers.
Easy automation can reduce assembly costs.
No other fastener, adhesive, solvent, welding, or special
equipment is needed.
Design can minimize the risk of improper assembly.
Can be designed to engage and disengage.
Factors Regarding Snap-Fits
Snap-fits that are assembled under stress will allow creep, a
plastic's deformation under load (tension, compression or
flexure) over time.

It is difficult to design snap-fits with hermetic seals. If the
beam or ledge of the snap-fit relaxes, it could decrease the
effectiveness of the seal.

Snap-fits can be damaged by mishandling and abuse prior
to assembly.

The key to successful snap-fit design is to have adequate
holding power without exceeding the elastic or fatigue
limits of the material.
Press Fits
Press fitting refers to two parts being
pressed together, making an
interference fit.
o An interference fit occurs when the
inner diameter of the hole is slightly
less than the outer diameter of the part
being inserted. When the two parts are
pushed together, they stick.
A common example is the forced
insertion of a metal pin or shaft that is
slightly larger than a plastic hub or
boss it is inserted into.
Press fitting is a simple, low-cost
method for assembling parts or
components.
Use of Press Fits
Used in the telecommunications and computer industries, as well as in
automobiles, airplanes, office equipment, and consumer goods.

Press fitting is a lower quality fitting process. However, once a press fit is in
place, it will not come loose.

The particular application dictates whether a press fit or other fastening
method is used. Press fits are sometimes used to get a complete alignment
between two pieces.

Press fits are also used to prevent bearings from spinning. It is a good
fastening method for components that undergo temperature fluctuations,
such as automotive assemblies. Regardless of the temperature, the
interference fit or force between the two parts is always there.
Living Hinges
Thin sections of plastic that connect two
segments of a part to keep them together
and allow the part to be opened and
closed.
Typically these are used in containers that
are used in high volume flexing
applications such as toolboxes, fish tackle
boxes, file card boxes, etc.
The materials used to make a living hinge
are usually a very flexible plastic such as
polypropylene and polyethylene. These
can flex more than a million cycles
without failure.
Bosses
Projection designed into a plastic
part to add strength, facilitate
alignment during assembly, or to
provide for fastening.

Bosses are used for the purpose of
registration of mating parts or for
attaching fasteners such as screws or
accepting threaded inserts (molded-
in, press-fitted, ultrasonically or
thermally inserted).
Hot Gas Welding
Most widely applied in the
fabrication of plastic
assemblies.

Involves the use of various
butt joints & hot gas from a
welding torch to melt filler
material between pieces of
an assembly to create a
weld.
Ultrasonic Welding
The most common thermal method for
joining small and medium-sized parts
of amorphous and crystalline plastics.

The process normally lasts less than 2
seconds and forms a continuous,
leak-proof joint that often is as strong
as the base material.

Done using equipment that applies
high-frequency energy (20 to 40 KHz)
directly to the interface between
parts.

Laser Welding
Involves use of a laser to melt
the bond line between two
parts to form a weld.

This method is a fast,
economical, and safe way to
weld compatible plastics
having similar melt
temperatures.

Vibration Welding
Done by parts being rubbed
together to create frictional heat.

Rubbing usually involves amplitudes
of 0.1- to 0.2-in. and frequencies of
120 and 240 Hz.

It creates strong joints and works
best with large parts that have
irregular joint interfaces
Spin Welding
Joins parts with circular joint
surfaces using relatively simple
equipment, sometimes just a
drill press.

Involves holding one part firmly
and pressing a rotating part
against it at a steady pressure.

The weld usually forms in less
than 3 seconds.
Mechanical Fasteners
Readily available, easy to install, and
usually allow for nondestructive
disassembly.

Often have high assembly costs and require
that extra parts be stocked.

Most fasteners used with metals also work
with plastics (e.g., screws, bolts, nuts and
lock washers).

When selecting metal fasteners, be aware
that these components can overstress
plastic parts. This can be prevented through
proper design, using the appropriate
fastener and torque-limiting drivers.
Threaded Metal Inserts
Permanently installed in molded
bosses, eliminate the need for a
nut, simplifying the assembly.

Can include female threads,
threaded male studs, locating
pins, and bushings.

Ultrasonically-installed inserts are
especially popular, because the
surrounding plastic melts around
the insert, make it strong and
relatively free of stress.
Metal Rivets
Allow for fast, permanent
assemblies.

Should have large heads to spread
the load.

Rivet should be formed against the
metal part of an assembly or
against a metal washer if both parts
are plastic.
Stamped Sheet Metal Fasteners
Provide light-duty threads or push-on assemblies. Push-
nuts, for example, are simply pressed onto plain, molded
plastic studs or bosses in permanent assemblies.
Easy to install, inexpensive, and vibration-proof.
Another such fastener, boss caps (cup-shaped parts
pushed onto a plastic boss), add partial metal threads
for self-tapping or sheet metal screws, and reinforce the
boss against the expansion forces of the screw.
Molded Plastic Screws, Rivets and Other
Similar Fasteners
Used for light-duty plastic assemblies, especially where
appearance is important, such as to attach trim and
faceplates.
Solvent Bonding
A liquid applied just before assembly dissolves the joint
surfaces. This is enough for a weld to remain after the
solvent evaporates. This method is limited to compatible
materials that dissolve in the same solvent or solvents.

The chemical resistance of many plastics limit this
method from being used.
Adhesive Bonding
Occurs when a third substance bonds a plastic to another plastic or to
metal, rubber, ceramic, glass, or wood.

Adhesives frequently used with thermoplastics include epoxy, acrylic,
polyurethane, phenolic, rubber, polyester and vinyl. Cyanoacrylate
(superglue) adhesives are popular because they work rapidly.

Many adhesives contain solvents that partially dissolve the plastic surface,
which improves adhesion.

Surface preparation is also critical for successful adhesion.

Many materials must be roughened or etched to eliminate overly smooth
surfaces. They also may need thorough cleaning because grease, mold
release compound, and other contaminants can spoil a bond.