nanoSTAKE Design Guidelines

Download these guidelines.

Round Boss Design

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.

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

Rectangular Boss Design

Example Rectangular Boss Dimensions

All nanoSTAKE punches are custom-designed for their application. This allows each stake point to be optimized for maximum strength.

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

Boss Spacing

NanoSTAKE modules are 8 mm in diameter at the tip.

Maintain 10 mm boss centerline spacing to allow for adjustment and variation.

Boss Angles

Best Design

Great Design

Poor Design

Learn how to design for nanoSTAKE.

 

Have a question?

Please contact us with any questions.

Contact us.