Light Alloy Die Casting: Solving Thread Challenges

Aluminum and magnesium die castings are the core structural materials in NEV vehicles and consumer electronics, but they share a common weakness: directly tapped threads in thin walls strip easily and wear quickly.

The Problem

Aluminum die castings are far softer than steel. Tapping an M6 thread directly into a 2 mm cast wall leaves the first engaged thread carrying roughly 50% of the clamp load — after a few reassembly cycles, the thread strips. This is why phone frames, motor housings, and battery enclosures universally require threaded inserts.

The Solution: Thread Inserts

• Wire thread inserts (HELICOIL-type): Cold-formed from SUS304 diamond wire (HRC43–50, tensile ≥1370 MPa). When installed into light-alloy holes, they create Grade-12 internal threads compatible with Grade 8.8+ bolts. Available in free-running, locking, and tangless styles, sizes M2–M39.
• Brass inserts (heat-stake/ultrasonic): Pre-molded into plastic parts for durable threads.
• Self-tapping inserts (Type 302/308): Form their own threads in pilot holes — ideal for repair and low-volume runs.

Toprecision Capabilities

Toprecision supplies the full range of thread inserts — wire inserts, brass inserts, self-tapping inserts, and keenserts — along with installation tools and engineering support. Our inserts are used in NEV motor housings, smartphone frames, and medical devices.