Switching from Weld Fasteners to Clinch Fasteners | PEM
Why Switch from Weld Fasteners to Clinch Fasteners - Beyond the Obvious
For many design engineers, the shift from weld fasteners to self-clinching fasteners has already begun—and often, it's driven by two key motivators: environmental impact and cosmetic appeal. But what many discover after making the switch is that the real value goes far beyond those initial advantages.
Let’s break down why clinch fasteners are increasingly becoming the go-to solution—and how they’re transforming real-world applications.
Environmental Advantages
Switching to self-clinching fasteners significantly reduces the environmental footprint of the fastening process:
- Lower energy consumption - No high-voltage welders required.
- No shielding gases or consumables - Cleaner process with fewer resources.
- More stable production - No risks tied to voltage fluctuations or brownouts.
Cosmetic Benefits
Clinch fasteners also improve product aesthetics and streamline surface treatments:
- No weld splatter - Cleaner panels and components.
- Pre-finishing is possible - Panels and fasteners can be plated before assembly.
- No thermal distortion - Eliminates warping caused by welding heat.
Design Advantage - Where It Gets Really Interesting
Once design engineers adopt self-clinching fasteners, they often uncover additional advantages that can significantly enhance product design and assembly:
- Precise thread positioning – Improved accuracy for critical alignments.
- Compatibility with dissimilar metals – Design flexibility that welding can’t match.
- Stronger threads – Heat-treated clinch fasteners provide added durability.
These benefits apply across a wide range of thread sizes—from tiny M1 fasteners in mobile devices to large M10 studs in heavy-duty automotive components.
Real-World Applications
Mobile Phone Innovation
One OEM had been welding M1.4 standoffs made from 300 series stainless steel into matching stainless panels. But they ran into limitations: welding made it difficult to place fasteners close to panel edges and achieve tight tolerances on thread location.
After exploring self-clinching fasteners, they redesigned their next-generation device using M1.4 clinch standoffs. The payoff was immediate—more accurate placement and better structural integrity. Even better? In the following year’s model, they clinched the same standoff into an aluminum panel—something that wasn’t possible with welding. Design freedom unlocked.
Automotive Torque Converter Ring
In another case, a design engineer faced persistent issues with eight M10 weld studs on a torque converter ring. Each stud deviated slightly from center, and the combined misalignment caused unacceptable wobble during cycle testing.
The solution? Replace all eight weld studs with self-clinching studs. But during testing, something unexpected happened—they found they could reduce the count to just four M10 clinch studs while still meeting performance requirements. This change didn’t just improve accuracy—it eliminated four studs, four washers, four nuts, and all associated handling costs. That’s a win for both design and budget.
The Bottom Line
Switching to self-clinching fasteners doesn’t just solve surface-level problems—it opens doors to smarter design, better performance, and lower total installed costs. Whether you’re working on compact consumer electronics or rugged automotive systems, it’s worth looking beyond the obvious.
Thinking about making the switch? You might discover more than you expected.