BigHead bonding fastener customization targets composites design challenges

Source | bigHead

BigHead Bonding Fasteners Ltd. (Verwood, U.K.) offers a bespoke online customization service that enables engineers and designers to modify standard bonding fastener products to meet the specific structural, environmental and assembly requirements of their composite applications.

Highlighted via bigHead’s Customize website page, the service covers nine configurable options spanning thread geometry, head form, collar design and surface finish. The offerings are organized around when and why each modification is appropriate, along with which product types are compatible.

Thread and geometry options. Thread length variants allow stud and collar products to be adjusted in 1-mm increments — shorter variants reduce intrusion into surrounding spaces, while longer ones increase thread engagement or span greater distances. ISO 4753 end-forms modify the tip of externally threaded studs to reduce cross-threading, prevent nut loss and support self-alignment during manual or automated assembly.

For applications requiring broader load distribution, bigHead offers two enlarged head formats. The large round Head measures 50 mm in diameter and provides approximately twice the load-spreading area of standard head designs; the large square Head, at 58 × 58 mm, offers approximately 3.5 times the load-spreading area. According to bigHead, both are suited to thin or lower-stiffness substrates where localized bending or buckling under load is a concern — common considerations in composite panel construction.

Collar and locking features. Three collar-specific customizations address sealing and installation performance. A closed blind collar pairs a blind head with a blind flange collar to create an airtight seal, preventing liquid resin or molten polymer ingress into the threaded section during molding — a relevant concern in wet layup and infusion processes. A closed sighted collar provides similar fluid protection while retaining thread access through a sighted head. A reverse weld collar flips the standard weld orientation for applications where installation loads may exceed standard weld strength, or where a smooth mating surface is needed for component seating or mold shut-off.

Anti-loosening and lock nut features add integrated locking and rotation-resistance to internally threaded nut products, addressing fastening relaxation or component movement under vibration.

Surface finishes and coatings. BigHead also offers alternative finishes and coatings across most of its product range. According to the company, coating options address corrosion resistance, surface cleanliness, friction control and visual appearance requirements. The company’s guidance page lists additional details on compatible coatings for reference and verification.

The customization service sits within bigHead’s broader bespoke offering, which also includes a Create pathway for fully new fastening solutions developed in collaboration with bigHead’s engineering team. Visit the company’s website for more information.