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nanoSTAKE Design Guidelines

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How to design for plastic staking

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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

Have a question?

Please contact us with any questions.

Contact us.