Mechanical Assembly Services
As a leader in mechanical assembly, we take pride in offering a full range of in-house hardware installation and mechanical fastening options that cater to your specific requirements. Our highly skilled technicians are well-versed in the art of permanent, semi-permanent, and non-permanent mechanical assembly, and employ a variety of methods to provide optimal solutions for your needs.
We understand the critical importance of choosing the appropriate options to satisfy your specific requirements. This is why we have sheet metal engineering and assembly experts on hand who work closely with you, providing expert guidance to help you determine optimal connectors for your parts, their strategic placement in the assembly, and the most effective timing for their installation.
Rest assured that our experienced team is committed to delivering superior quality and efficiency in every aspect of the assembly process. By considering factors such as the materials used, desired durability, and permanency of the assembly, our technicians customize the sheet metal assembly process for each client to make it as efficient and cost-effective as possible.
Mechanical Fastening Options
Our in-house mechanical assembly fastening options include threaded fasteners, non-threaded fasteners, integral mechanical attachments, and thermal joining and welding.
Threaded Fastening
Our most popular and effective method of joining sheet metal parts is with threaded fastening. This method involves the mechanical attaching of two or more parts into a sheet metal assembly using threads as attachments. It is ideal for use where disassembling and reassembling are required for future maintenance, adjustments, part replacement, or any sort of work that is not permanent. We have experience with a variety of threaded fastener options. Common threaded fastener requirements fulfilled at PEKO include self-clinching fastener and loose hardware installation.
- Loose hardware includes things like screws, nuts, studs, bolts, tapping screws, and more.
- Self-clinching fasteners, like PEM nuts, are mechanically pressed into sheet metal during fabrication to become a permanent part of the panel, enclosure, or bracket. They offer strong, secure joints and attachment in sheet metal or panels that are too thin to tap, and better thread strength than tapped holes. They also provide design flexibility that simplifies and expedites component mounting and assembly operations for shorter production cycles and cost savings.
Non-Threaded Fastening
Non-threaded fastening is another common mechanical assembly method employed at PEKO. This method uses simple yet versatile fasteners like pins, washers, retaining rings, dowels, keyrings, rivets, and adhesives to make connections with minimal effort. With this method, you don’t have to worry about threads or complex fixtures—all you need are pre-drilled holes to attach and create durable bonds that will stand the test of time.
- Pins provide easy, reliable non-threaded fastening mechanisms—they can be used as locking devices, locating elements, pivots, and bearing faces. They come in a variety of styles (straight or tapered, with head or without) that make them compatible with many assemblies.
- Washers help provide a secure seating point for bolts and screws to give assemblies the strength and stability they need to perform optimally. They function to distribute loads and stresses over large surfaces and are integral for applications subject to shock and vibration.
- Sheet metal riveting provides a lasting and secure way to fasten components together. This method utilizes an automatic pneumatic hammer to insert rivets, which are bolt-like fasteners, through sheet metal in a way that deforms and permanently fastens components. The result is a strong connection, comparable to welding but at a lower cost. It is ideal for assemblies that require shear strength and for joining different types of materials. It also excels in challenging environments, withstanding harsh conditions, such as dampness, high vibrations, and heavy loads. This makes it perfect for structural assemblies subjected to fluctuating temperatures and pressures.
- Adhesive bonding is another effective way of permanently joining two sheet metal surfaces that utilizes liquid adhesives and tapes, effectively eliminating the need for any additional fastening components. It can be used on various types of materials without requiring penetration or high temperatures. It is effective for bonding dissimilar metals, joining irregularly shaped surfaces, and forming a protective seal against corrosion. However, clean surfaces, tight clearances, and longer bonding times are necessary.
Integral Mechanical Attachment
Integral fastening utilizes formed areas incorporated into sheet metal during its fabrication, like embossed protrusions, edge seams, snap-fit joints, and folded tab and slot assemblies, to interlock components and form assemblies. This fastening method provides strong and secure connections without the need for additional bonding agents or fastening processes like with other mechanical assembly techniques. Integral fasteners considerably reduce the complexity and cost of assembling sheet metal, allowing for faster completion with a lower risk of errors. They are often used in the development of designs that are optimized for ease of manufacturing and assembly (DFMA).
- Clinching is a high-speed mechanical fastening technique that works by embossing protrusions between two sheets of metal that interlock them together to form watertight, permanent joints. This process not only provides a faster, cleaner, cheaper, and easier alternative to traditional fastening methods, but it produces no sparks nor burn marks and is capable of efficiently joining together mismatched materials, a task which welding often falls short. However, clinched joints are generally not as strong as resistance spot welding and self-piercing riveting. It is ideal for use in non-visible, non-critical joints.
- Hemming and seaming are similar methods of integral fastening in which a sheet metal edge is rolled over onto itself. Hemming allows the sheet metal edge to be rolled over flush to itself to reinforce an edge with extra strength and hide any burrs or rough edges that may be present upon completion. Seaming goes a step further by joining the edges of two separate materials, or the opposite edge of the same part, into one fastening seam that offers extra stability and protection against sharp edges.
- Tab and slot assemblies are a fastening technique that uses tabs (also known as legs, ears, or tongues) that are formed on one part and then bent up at an appropriate angle, inserted into slots in a mating part, and folded over to form a secure joint that permanently or semi-permanently attaches the parts to one another. These connectors work well in applications where parts need to be securely held together before additional welding or assembly processes can take place, such as when a bracket needs to be welded onto a part.
- Snap fits offer a simple, quick, and cost-effective method for connecting two sheet metal parts. They work by utilizing a small protrusion, such as a stud or hook, that deflects during assembly and locks into place to trap the other part. There are several different types, such as cantilever, annular, and torsion, to cater to various design scenarios. These connections reduce material costs and part inventories, improve aesthetics and ease of assembly, and offer better disassembling without damaging the parts or losing quality. They have become a popular alternative to screw fasteners in many critical assembly areas.
Thermal Joining & Welding
We can also provide in-house sheet metal welding to create strong, physical bonds for mechanical assembly by permanently fusing two parts together into one. Our teams employ a variety of specialized precision welding techniques, like MIG welding, TIG welding, resistance/spot welding, robotic welding, brazing, and soldering. It is an ideal option for structural components that require a strong, long-lasting structure.
Our technicians strive to provide superior workmanship while considering all elements to create the utmost efficiency for your budget and timeline production goals. Get started with PEKO today. Contact us to learn more about how we can handle all your mechanical assembly needs.