Custom Micro Screws: Complete Guide
Screws play a vital role in all types of projects, and you can have custom micro screws designed.
If you are planning to come up with a new project and want to learn about micro screws, the guide below has all the information regarding custom micro screw manufacturing.
What are Custom Micro Screws?
Custom screws are used in applications where standard screws cannot be used. These custom micro screws cater to the unique requirements of the project.
These screws are suitable for precision-oriented applications like aerospace, electronics, and medical. These industries cannot tolerate even a minor deviation.
These custom screws are made using versatile materials which cater the application requirements like corrosion resistance, weight considerations, and durability. These screws even ensure aesthetics and integrity.
Benefits of Custom Micro Screws
Custom micro screws are used widely in many applications; some of the benefits of custom micro screws are as follows:
- Custom micro screws are designed so that they meet the precise requirements of applications for which these are used.
- The custom micro screws can be optimized to meet the specific resistance to wear, corrosion and offer required strength.
- The custom micro screws can be made with versatile materials; these materials are chosen based on the environment they are opted for use. For instance, stainless steel micro screws can be chosen for an environment exposed to corrosion and high temperature.
- Certain industries need to fit very small components with perfection. Hence, these custom micro screws can be designed in the tiniest size to cater for precision.
- As they have the exact dimensions required for the application, the final product tends to have better performance and quality.
6 Drive Types for Custom Screws
The six drive types for custom screws which are commonly opted for are as follows:
Phillips Drive
Phillips drive has a cross-shaped slot, which is used for self-centering characteristics. The chances of slippage are very less in this type of screw. It is suitable for automated production lines and is also used in consumer electronics.
Torx Drive
Torx drive has a pattern of star shape. It has high torque transmission and less risk of cam-out. It is suitable for applications that require high precision, such as electronics and aerospace.
Slotted Drive
Slotted drives have a straight slot and have a very simple operation, but they can cam out. These are used in applications that need precise control of torque.
Tri-Wing Drive
Tri-wing drive has a slotted pattern in a triangular pattern and is used in applications that need tamper and stress resistance. It is commonly used in electronic devices that have a high control over access for adjustments and repairs.
Allen Drive (Hex Socket)
Allen drive has a hexagonal socket and works with an Allen key. It offers excellent torque and is used in automobile and machinery applications.
Robertson Drive (Square Recess)
Square recess offers cam-out resistance and a high capacity of torque. It is very commonly used in construction and woodworking as it is easy to use and holds strongly.
Custom Micro Screws Head Styles
The head style designed in custom screws requires balancing the screw fist and meets the specific application requirements. The head style should meet the space, torque, and ease of assembling requirements.
Moreover, the head style must have an aesthetic appearance in applications where they are visible. The main goal is to create a screw head that meets the design requirements, ease of use, and mechanical needs of the product.
Material Selection of Custom Micro Screws
The material of custom micro screws plays a vital role in performance and durability. Based on the environment it will be exposed to, the material is chosen for these screws. Some of the commonly adopted materials are as follows:
Metals
The different types of metals are commonly chosen for the micro screws; some of these metals are as follows:
- Stainless steel is a highly corrosion-resistant material that is suitable for applications that are exposed to moisture or outdoors.
- Aluminum is a lightweight material and is suitable for applications that are weight-sensitive.
- Brass is also resistant to corrosion and offers moderate strength. It is heavier than aluminum but not as heavy as steel. It is chosen for decorative purposes.
Plastics
- Nylon is suitable for insulation and also is lightweight. It offers chemical and corrosion resistance and works well in light-duty applications.
- Polycarbonate has excellent resistance against impact and corrosion and is used in applications that need transparency and lightweight screws.
- PVC is highly corrosion-resistant and soft and is used in plumbing applications as it resists chemicals and water.
- ABS is extremely strong and lightweight and, hence, can work in electronics and automobile applications.
The Importance of Precision in Size and Tolerance
The custom micro screws need to be highly precise and tolerant for the sizes; a minor deviation may lead to issues with their performance. Hence, the tolerance of these screws must be very carefully adjusted.
These custom micro screws are mostly used in sensitive applications like aerospace, electronics, and medicine.
The manufacturing process for these screws needs to be highly precise and consistent. The accuracy of these screws offers successful projects as they work with effectiveness.
Threading and its Impact on Micro Applications
The threading of custom micro screws is also vital for their functionality as it determines their fitting into different applications. The aspects like depth, pitch, and influence of profile are very important; they reflect the way the screw interacts with the material.
Industries like medical and microelectronics are highly precise industries, and they prefer fine threads for the micro screws.
These screws ensure a very strong grip and also secure the materials very well. The design of the thread also impacts the way screws can be fixed and removed.
The load distribution is also affected by the threading of the screw, and it impacts the wear resistance, durability, and strength in applications where they are used repetitively.
Manufacturing Method of Custom Micro Screw
The manufacturing process of custom micro screws varies based on the material and applications. Some of the commonly opted micro screw manufacturing processes are as follows:
CNC Machining
CNC machining is one of the most precision-oriented methods which helps to manufacture micro screws. The process works using CNC-controlled machines, which have highly accurate and detailed manufacturing capabilities.
The block of material is carved to manufacture the micro screw based on the custom design. This process helps manufacture micro screws with tight tolerance, and industries like aerospace and medical use it.
Swiss Screw Machining
Swiss screw machining or Swiss turning is a machining process that helps manufacture micro screws with the help of a lathe.
The workpiece is fixed and rotated, allowing the lathe to cut the workpiece and derive the micro screw. The micro screws that have complex geometry are usually manufactured through this process.
Thread Rolling
The thread-rolling process creates threads on the micro screws. The process starts by pressing a die that is shaped on the workpiece and rotates. The process helps to create strong threads and offers fatigue resistance.
Cold Heading
The process of cold heading involves a metal wire which is cut into the given length, and then a screw shape is formed at room temperature.
This process is suitable for producing custom micro screws in mass volume, and it offers strength to these screws with work hardening. These micro screws are mostly used in the automobile industry.
Micro Injection Molding
The process of micro injection molding helps in producing micro screws that are manufactured using plastics.
The process of injection molding works by injecting molten plastic into the mold, which is left for solidification. The process is suitable for manufacturing plastic screws which are highly precise and suitable for the electronic industry.
Applications of Custom Micro Screws
Custom micro screws are used in many industries, and some of their applications are as follows:
Electronics
Electronics are of varied sizes, and each of them requires different screws to fix components. Microelectronics usually need micro screws as they can easily align the components.
Some of the devices like mobiles, tablets, circuit boards, and smartwatches are assembled using micro screws.
Medical
Micro screws are used in the medical industry for assembling surgical tools, orthopedic implants, dental implants, and even in diagnostic equipment. The precision of these micro screws tends to cater to the medical industry with highly accurate fixation.
Aerospace
The aerospace industry requires custom micro screws, which are strong, lightweight, and precise; aircraft components and satellites tend to have these.
Automobile
Micro screws help in fastening electronic systems and sensors of the engine. They are especially used in motorcycles, racing cars, and electric vehicles, as precision is significant here.
How to Balance Cost and Quality?
Custom micro screw selection is successful when there is a balance between quality and cost. The low-cost screw helps save upfront costs, but in the longer run, the high cost of maintenance and failure risk is present.
Whereas, when you invest in high-quality screws, the cost is high, but the performance and durability are top-notch.
The key to success in these custom micro screws is to choose the screws with moderate cost and also meet quality standards.
Start Your Custom Micro Screw Project with DEK
If you are looking for high-quality and cost-effective custom micro screws which offer precision, you can consider DEK. We offer multiple methods of manufacturing these micro screws– customized according to your specifications and precision.
So, get in touch with us today and specify your application requirements for the custom micro screws.
Conclusion
The significance of custom micro screws in multiple applications plays a vital role. The guide above must have given you an insight into the types of micro screws and manufacturing processes.
Understanding all these details helps you make informed decisions regarding micro screw selection for your applications.
