Next-Generation Flow Drill Fastener
Benefits
Fastening into up to 10mm thick aluminum without clearance holes
Eliminating clearance hole collisions with high-strength top layers
Resisting joint leaks with or without clearance holes
Reducing installation time
Suppressing debris through improved point geometry
Improving material flow in brittle casting materials
Features
The OptiFlow™ fastener's modularity allows the designer to build their custom solution by selecting different head, thread, and tip design features to optimize required installation and joint performance.
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HEAD |
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LW: |
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SL: |
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SH: |
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FS: |
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TD: |
Traditional |
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THREAD |
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FF: |
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RH: |
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Traditional (Metric) |
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TIP |
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LT: |
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HP: |
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LH: |
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Traditional |
OptiFlow™ is the latest flow-drilling fastening technology capable of hole forming and self-threading into target mating materials. Flow drill fasteners utilize a pointed tip and frictional heat to soften substrate materials, allowing a hole to be “flowed” through them before forming threads into the created hole. OptiFlow™ was developed to improve traditional flow drill fastener designs, such as FDS®. Traditional flow drill fastener designs are over 25 years old and have several limitations, reducing their utilization in modern manufacturing. Some limitations include the inability to penetrate thick or high-strength materials, lack of leak resistance, downtime due to clearance hole collisions, poor bushing formation in castings, and debris generation. OptiFlow™ takes an innovative modular approach to flow drill fasteners. OptiFlow™ comprises various design innovations to traditional flow drill fasteners. Each design innovation solves a limitation of traditional flow drill fastening, and the designs can be combined to optimize the fastener for each application or range of applications.
Data Sheet(s)
HEAD DU: Deep Undercut
Allows joining of thicker top layers without clearance holes
- Reduces ‘sheet gaps’ by drawing more material upward
- Recommended for use with External Torx Plus® drive
HEAD SU: Sealing Head
Sealant material applied to the outer cavity ring
- Compatible with no clearance hole joints with inner cavity capturing the material flow
- Integrates large washer design
HEAD LW: Large Washer
Washer head diameter larger than traditional design- Allows for an increase in clearance hole diameter to reduce installation ‘strikes’
- Enhanced load distribution in crash events
HEAD SL: Underhead Sealant
Reduce leak rates in water-sensitive areas- Requires clearance hole in top material(s)
- Wide variety of sealants available to meet joint requirements
HEAD FS: FlowStud®
Combines two fasteners into one
- Non-flow drill end is configurable to your needs
- Allows for process consolidation between weld studs and flow drill fasteners
THREAD FF: FastFlow®
Triple helix thread shortens thread forming and tightening steps by 60%
- Same penetration characteristics of standard FDS®
- Critical joint characteristics are maintained
THREAD RH: Rolok HS®
Optimized thread geometry for high-strength steels
- Thread reduces collapse, allowing usage in up to 1mm 1200MPa steels
- Typically used on M4 high-strength variant
TIP RH: Low Torque
Reduces thread-forming torque by 20-40%
- Allows for increased joint thicknesses (up to 10mm)
- Increases available thread engagement
TIP HP: High Performance
Optimized tip shape significantly reduces debris generation
- Reduced ‘bushing’ cracking in cast materials
- Improves ‘bushing’ formation in extruded materials
TIP LH: Combination of LT and HP Tips
Allows for increased joint thicknesses (up to 10mm)
- Increases available thread engagement
- Optimized tip shape significantly reduces debris generation