Complete Assemblies

Using a self-tapping screw is often more cost-effective as it eliminates the secondary tapping operation entirely. However, tapped holes offer a stronger, more reliable thread for disassembly.

Resistance (Spot) Welding is much faster and more cost-effective for high-volume joining of thin sheet metal assemblies. TIG/MIG is reserved for structural, low-volume, or visually critical joints.

Standard hardware (screws, nuts, bolts) is vastly cheaper and more readily available than custom-machined fasteners. DFM dictates always using standard sizes to reduce costs and lead times.

The material thickness must be sufficient to support the nut’s collar. The hole size must be precise and consistent to ensure proper seating, and surrounding material must have enough strength to prevent push-out.

Use the recommended clearance hole size (e.g., 0.140″) for proper assembly alignment, or the minimum clearance size (e.g., 0.125″) for maximum thread engagement if tapping is used.