Last Updated: 22 May 2007

Your design, our commitment

Threaded Fasteners
Protogenic can handle the installation of threaded fasteners into your functionally finished SLA's, sintered nylon parts, Polyjet parts, and cast urethanes,
when your bosses are sized per the tables below. We have four types of fasteners available; Tapped Threads, Self-threading inserts, Helicoils, and glued-in
brass inserts. Self-threading inserts and tapped threads have the greatest pull-out strength of the four, and are recommended for more "production-oriented"
prototype jobs. Helicoils are more robust than the glued-in threaded inserts, but often require a deeper boss size. Glued-in threaded inserts are more suited
to work with shallow bosses and thinner walls, but are the least robust of the four options.
We recommend you use threaded fasteners rather than self-tapping screws for prototype parts you intend to assemble more than one or two times. For your
convenience, we have supplied the dimensions that work best with our inserts and installation processes. Remember, the sizing below is for our prototype
applications, always consult your tool maker or injection molder for production boss sizing.

Tap Drill Sizing: Best for Nylon

Thread

Hole ID

Thread

Hole ID

Thread

Hole ID

2-56
4-40
6-32
8-32
10-32

0.067
0.086
0.104
0.136
0.156

-20
-20
-14
NPT
NPT

0.196
0.453
0.766
0.339
0.4375

M2 x .4
M2.5 x .45
M3 x .5
M4 x .7
M5 x .8

0.062
0.081
0.098
0.130
0.165

Helicoils: Best for SLA's, Cast Urethanes, and Sintered Nylon

Boss ID

Boss OD

Boss Depth

Minimum Boss OD - Minimum Boss OD MM

English

Thread

Length

Drill/Core size - MM

Drill/Core Size English

Minimum Hole
Depth - MM

Minimum Hole
Depth - English

M2.5 x 0.45
M3 x 0.5
M3.5 x 0.6
M4 x 0.7

1.5 Dia.
1.5 Dia.
1.5 Dia.
1.5 Dia.

2.55
3.15
3.70
4.20

0.104
0.125
0.144
0.166

5.82
6.35
6.83
7.39

0.229
0.250
0.269
0.291

5.55
6.50
7.65
8.80

0.320
0.360
0.400
0.450

2-56
4-40
6-32
8-32
10-32
1/4 - 20

1.5 Dia.
1.5 Dia.
1.5 Dia.
1.5 Dia.
1.5 Dia.
1.0 Dia.

2.38
3.05
3.81
4.45
5.16
6.83

0.094
0.120
0.150
0.175
0.203
0.269

5.56
6.22
6.99
7.62
8.33
10.01

0.219
0.245
0.275
0.300
0.328
0.394

5.08
6.85
8.51
9.53
10.41
12.70

0.320
0.370
0.435
0.475
0.510
0.500

Brass Threaded Inserts: Best for SLA's, Polyjet, and Cast Urethanes
Boss ID

Boss OD

Boss Depth

Minimum Boss OD - Minimum Boss OD MM

English

Thread

Length

Drill/Core size - MM

Drill/Core Size English

Minimum Hole
Depth - MM

Minimum Hole
Depth - English

M2 x 0.4
M2.5 x 0.45
M3 x 0.5
M3.5 x 0.6
M4 x 0.7

2.900
3.400
3.800
3.800
4.700

3.53
4.32
5.51
5.51
6.30

0.139
0.170
0.217
0.217
0.248

6.71
7.50
8.69
8.69
9.48

0.264
0.295
0.342
0.342
0.373

4.00
4.80
6.00
6.00
6.80

0.157
0.189
0.236
0.236
0.268

2-56
4-40
6-32
8-32
10-32
1/4 - 20

0.115
0.135
0.150
0.185
0.225
0.300

3.53
4.32
5.51
6.30
7.49
9.47

0.139
0.170
0.217
0.248
0.295
0.373

6.71
7.49
8.69
9.47
10.67
12.65

0.264
0.295
0.342
0.373
0.420
0.498

3.56
4.06
4.45
5.21
6.35
8.26

0.140
0.160
0.175
0.205
0.250
0.325

Self-Threading Inserts: Best for Production Urethanes, Polyjet, and Sintered Nylon
Boss ID

Boss OD

Length

Drill/Core size - MM

Drill/Core Size English

M2 x 0.4
M2.5 x 0.45
M3 x 0.5
M3.5 x 0.6
M4 x 0.7

4.750
5.940
7.140
7.140
8.330

3.28
3.96
5.03
5.03
5.84

0.129
0.156
0.198
0.198
0.230

8.36
9.04
10.11
10.11
10.92

2-56
4-40
6-32
8-32
10-32
1/4 - 20

0.187
0.234
0.281
0.328
0.375
0.484

3.28
3.96
5.03
5.84
6.86
8.71

0.129
0.156
0.198
0.230
0.270
0.343

8.36
9.04
10.11
10.92
11.94
13.79

7401 Church Ranch Blvd Suite 206

Boss Depth

Minimum Boss OD - Minimum Boss OD MM

English

Thread

Westminster, Co 80021

Minimum Hole
Depth - MM

Minimum Hole
Depth - English

0.329
0.356
0.398
0.398
0.430

5.72
7.14
8.56
8.56
10.01

0.225
0.281
0.337
0.337
0.394

0.329
0.356
0.398
0.430
0.470
0.543

5.72
7.14
8.56
10.01
11.43
14.76

0.225
0.281
0.337
0.394
0.450
0.581

303- 252-0212

www.protogenic.com