Find out how we were able to fasten thin and delicate composite panels without compromising structural integrity

Precision is vital in the aerospace industry, down to the very smallest detail. No corner can be cut, and safety depends on it.

When it comes to aircraft seating, there’s also a need for comfort and durability, particularly in first-class cabins, where an even greater level of quality and luxury is
expected.

Combine that with a need to produce components with tight tolerances, at high volumes, without compromising safety or quality, and it’s clear that an efficient production process, using high performance parts, is absolutely vital.

The challenge:
We were approached by a leading global manufacturer of first-class aircraft seating who had a critical challenge. They needed reliable threaded inserts to be installed into each seat’s composite panels, specifically in the thinner, outer edges of an 8mm foam panel with a carbon-fibre overlay.

The panel’s delicate structure required a solution that would ensure both secure fastening and long-term durability, without compromising the integrity of the composite material.

A bespoke solution from the Tappex Technical Advisory Service experts
When you’re dealing with specific challenges, a bespoke solution for that particular problem is often needed – one that you can easily implement and roll out at scale.

That’s exactly what we did here with our Technical Advisory Service team recommending a custom approach that integrated seamlessly into the customer’s manufacturing process.

We advised them to incorporate a resin block during the lay-up process. Once cured, this resin could be precisely machined to create a solid foundation, ready to accept our Trisert 3® selftapping inserts.

The Tappex Trisert 3® insert has three patented cutting features to provide more balanced cutting forces and therefore reduced installation torque. The head diameter is designed to fit exactly the counter bore of the prepared hole specified, resulting in a neat flush-fit finish where required.

This strategy provided a secure and durable method of inserting threads into the composite panel’s thinner sections.

Implementation
The customer agreed with our proposed solution and produced prototype samples. To ensure optimum results, we also demonstrated the use of our ElecArm® installation equipment.

The Tappex ElecArm® uses a robust vertical support column and horizontal-sliding balance arm with spring support, and is fitted with an electrically powered torque-settable screwdriver. This runs on 230/240v mains and is available in five torque ranges from 0.29Nm up to 25Nm value.

This was invaluable in improving both the accuracy and alignment of the inserts, and speeding up the installation process.

Expectation-exceeding results
The aircraft seating manufacturer was extremely satisfied with the results as the approach not only met, but exceeded their expectations, with a reliable and durable solution for their first-class seating. We also presented them with an installation method that speeds up the process, offering further efficiency savings, which is a critical factor in the competitive section in which they operate.They continue to purchase our industry-leading Tappex Trisert 3® threaded inserts as part of a new long-term partnership.The company’s lead design engineer for the project said: “For this particular challenge, we needed something that was high quality and durable, and that could be installed without compromising the integrity of the delicate, thinner sections of the composite panels in the seating.

“The experience and depth of knowledge the team at Tappex has was vital and they were able to develop a solution that met every challenge presented. By taking advantage of this expertise, we are now reaping the benefits of a bespoke solution designed for our specific needs, rather than trying to make a square peg fit a round hole.

“We’re delighted to have found something that not only does the job well, but exceeds the requirements outlined in the initial project scope.”

Choosing Tappex as your technical partner
Our Technical Advisory Service brings over six decades of experience in threaded insert technology to your design challenges, to ensure you get exactly what you need from day one.

By partnering with Tappex, you can access our vast inventory of 60 million standard inserts for quick off-theshelf delivery, as well as bespoke solutions. Our broad range of threaded inserts for plastics, woods, light metal alloys, and composite materials, coupled with our problem-solving expertise, results in cost-effective fastening solutions that are built to last.