nanoSTAKE Design Guidelines
Download these guidelines.
Notes:
- Hollow boss designs are OK to use with nanoSTAKE
- The recommended clearance hole diameter is 1.1D (1.25D is the maximum diameter)
- The maximum recommended boss height above the mating surface is 1.5D
- Add radius and chamfer to prevent A-surface sink and improve stake strength
Example Round Boss Dimensions
All nanoSTAKE punches are custom-designed for their application. This allows each stake point to be optimized for maximum strength.
See Examples
Here is a range of example boss dimensions that could be staked with the nanoSTAKE process. As a general rule, the punch volume is calculated to be 95% of the boss volume. This ensures the boss material fills and “packs out” the punch cavity. The maximum recommended punch volume is 47.8 mm³.
Smaller and larger volumes may be possible. Please contact us for feasibility testing.
| Diameter [mm] | Height [mm] | Boss Volume [mm³] | Punch Volume [mm³] | Cross-Sectional Area [mm²] |
|---|---|---|---|---|
| 2 | 2 | 6.3 | 6 | 3.14 |
| 2 | 3 | 9.4 | 9 | 3.14 |
| 2 | 4 | 12.6 | 11.9 | 3.14 |
| 2 | 5 | 15.7 | 14.9 | 3.14 |
| 2.5 | 2 | 9.8 | 9.3 | 4.91 |
| 2.5 | 3 | 14.7 | 14 | 4.91 |
| 2.5 | 4 | 19.6 | 18.7 | 4.91 |
| 2.5 | 5 | 24.5 | 23.3 | 4.91 |
| 3 | 2 | 14.1 | 13.4 | 7.07 |
| 3 | 3 | 21.2 | 20.1 | 7.07 |
| 3 | 4 | 28.3 | 26.9 | 7.07 |
| 3 | 5 | 35.3 | 33.6 | 7.07 |
| 3.5 | 3 | 28.9 | 27.4 | 9.62 |
| 3.5 | 4 | 38.5 | 36.6 | 9.62 |
| 3.5 | 5 | 48.1 | 45.7 | 9.62 |
| 4 | 3 | 37.7 | 35.8 | 12.57 |
| 4 | 4 | 50.3 | 47.8 | 12.57 |
Example Rectangular Boss Dimensions
All nanoSTAKE punches are custom-designed for their application. This allows each stake point to be optimized for maximum strength.
See Examples
Here is a range of example boss dimensions that could be staked with the nanoSTAKE process. As a general rule, the punch volume is calculated to be 95% of the boss volume. This ensures the boss material fills and “packs out” the punch cavity. The maximum recommended punch volume is 47.8 mm³.
Smaller and larger volumes may be possible. Please contact us for feasibility testing.
| Length [mm] | Width [mm] | Height [mm] | Boss Volume [mm³] | Punch Volume [mm³] | Cross-Sectional Area [mm²] |
|---|---|---|---|---|---|
| 2 | 1 | 1 | 2 | 1.9 | 2 |
| 2 | 1 | 2 | 4 | 3.8 | 2 |
| 3 | 1 | 1 | 3 | 2.85 | 3 |
| 3 | 1 | 2 | 6 | 5.7 | 3 |
| 3 | 1 | 3 | 9 | 8.55 | 3 |
| 3 | 2 | 2 | 12 | 11.4 | 6 |
| 3 | 2 | 3 | 18 | 17.1 | 6 |
| 4 | 1 | 1 | 4 | 3.8 | 4 |
| 4 | 1 | 2 | 8 | 7.6 | 4 |
| 4 | 1 | 3 | 12 | 11.4 | 4 |
| 4 | 1 | 4 | 16 | 15.2 | 4 |
| 4 | 2 | 2 | 16 | 15.2 | 8 |
| 4 | 2 | 3 | 24 | 22.8 | 8 |
| 4 | 2 | 4 | 32 | 30.4 | 8 |
| 4 | 3 | 2 | 24 | 22.8 | 12 |
| 4 | 3 | 3 | 36 | 34.2 | 12 |
| 4 | 3 | 4 | 48 | 45.6 | 12 |
| 5 | 2 | 2 | 20 | 19 | 10 |
| 5 | 2 | 3 | 30 | 28.5 | 10 |
| 5 | 2 | 4 | 40 | 38 | 10 |
| 5 | 2.5 | 4 | 50 | 47.5 | 12.5 |
NanoSTAKE modules are 8 mm in diameter at the tip.
Maintain 10 mm boss centerline spacing to allow for adjustment and variation.
Best Design
Great Design
Poor Design
Learn how to design for nanoSTAKE.
Have a question?
Please contact us with any questions.