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INSIDE THIS ISSUE EDITOR’S COMMENT
04 Product News
COVER PROFILE
08 Spirol – The firm shares its expertise on the benefits of 420 Chrome Stainless Steel coiled spring pins in dynamic applications
PRODUCT INNOVATIONS
10 Volt Industrial Plastics – How Plastic Fixings & Fasteners are a durable, lightweight and non-conductive solution for auto manufacturers and others
18 Rivit – Battery-powered tools, hydro-pneumatic riveting tools and monitoring systems are part of the firm’s innovative and reliable high-performance range
INTERVIEW
12 Rapid Industrial Fasteners –Investments at this UK manufacturer mean it can now handle more advanced and difficult to machine alloys
TECHNICAL INSIGHTS
14 Rotor Clip – Arming engineers with knowledge, via a new video, on the benefits and advantages of Wave Springs in manufacturing
15 Kistler – iBEAM Lab data analysis software now provides efficient measurement data for NVH tests, for the auto and other markets
16 Optimas – Analysis of the key role fasteners plays for electric vehicle operations, from thermal management to energy efficiency
OPINION
20 HTL Group – The five digital trends that are transforming numerous aspects of the aerospace and smart manufacturing spaces
INDUSTRY EVENTS
22 Automechanika – The key automotive sector event returns to the NEC in June, including input from key market players like the SMMT
24 Subcon – Supply chains under geopolitical uncertainties will be among the topical discussions taking place at this year’s Subcon
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INNOVATION AND FUTURE GAZING
We have dedicated a fair bit of space within this issue of Torque Direct to innovation, from the continued gains of digitalisation to the more nuts and bolts (literally) advancements taking place in the market.
Inevitably, artificial intelligence (AI) crops up in amongst our coverage of digital developments. Away from the controversies and the more bombastic predictions of what AI will be capable of, AI is of course already in use in the worlds of engineering and production to a greater or lesser degree, and also showing some interesting potentials too, including in the world of predictive maintenance. That’s an area that has come a long way in recent years, with significant positive implications for running costs. Smart components – that notify when they need servicing or replacing (a real boon when they’re in those expensive to reach places like off-shore wind farms) –coupled with some predictive maintenance, make AI a tantalising prospect for projects that do require regular maintenance.
AI undoubtedly has a big role to play in optimising many areas, from production lines to warehouse operations and will likely become increasingly important. As another tool available for industry, it offers huge potential, but with the limitations of any new tool. It’s unlikely AI will be able to ascertain where the next supply chain challenge will come from, for instance. But certainly one to watch, nevertheless.
Lest we forget, there’s plenty of less digitalorientated innovation covered in this SpringSummer issue of Torque Direct too, from new rivet hand tools to plastic fasteners breaking new ground in electric vehicle production and more, all on the following pages.
As
Jonathon Harker Editor Jonathon@torque-direct.com
FASTER BONDING FROM INTERTRONICS
To help manufacturers address the rising demand for bonding low surface energy (LSE) materials, such as polypropylene and polyethylene, adhesive specialist Intertronics has launched SCIGRIP® SG400LSE Methyl Methacry late Adhesive (MMA). SG400LSE helps elimi nate the need for costly and timeconsuming surface preparation and is applicable across industries including automotive, electronics, signage and assembly thanks to crossbonding capabilities with plastics, metals and composites.
SCIGRIP SG400LSE is a twocomponent 10:1 formulation tailored for bonding low surface energy plastics such as polypropylene, polyethylene, other polyolefins, and thermoplastic elastomers to metals, FRP and other plastics. Manufacturers, particularly in the auto motive and transport industries, want to utilise polypropylene (PP) in their designs. It is lightweight, costefficient, and impact resistant. It is popular because of its combination of performance, durability, and processability. PP is one of the most recyclable plastics, aligning manufacturers with their circular economy goals. But it is very difficult to bond due to an inherent low surface energy, usually requiring surface treatment for successful adhesion – and sometimes not bondable at all. SCIGRIP SG400LSE requires little
to no surface preparation to bond polyolefins, due to its excellent wetting properties, while still providing resistance to harsh environments and mechanical stresses.
“Low surface energy materials are notoriously difficult to bond,” explained Ben Swanson, Joint Managing Director at Intertronics. “The use of polypropylene, polyethylene, and various composites are on the rise and SG400LSE is specially designed to help bond these materials. It is versatile, able to create durable crossbonds with plastics, metals, and composites. It is an important enabling technology, bringing enhanced design capability in fields like automotive, marine and transport.”
Available in premeasured, sidebyside double syringe cartridges with static mixing nozzles for ease of use, SCIGRIP SG400LSE has fast cure time and high initial tack to facilitate efficient assembly processes, reducing production time and increasing overall productivity.
The adhesive exhibits no sagging, maintaining stability even when applicated vertically and boasts low exotherm properties, minimising heat generation during the curing process.
www.intertronics.co.uk
GREENER HOT MELT ADHESIVES
Adhesives, sealants and functional coatings specialist Henkel and Sasol, a global leader in FischerTropsch technology, are partnering to reduce the environmental impact of hot melt adhesives. Through the integration of Sasol’s newly developed SASOLWAX LC product range into Henkel’s TECHNOMELT® portfolio for the European, Indian, Middle Eastern and African markets, Henkel is delivering advanced adhesive solutions with a reduced carbon emission impact.
SASOLWAX LC100, produced via Sasol’s enhanced FischerTropsch process, delivers a 35% reduction in Product Carbon Footprint (PCF) cradletogate compared to proven baseline formulas without compromising on performance. As a dropin replacement in Henkel’s legacy formulations, it enables adoption across production lines while aligning with Henkel’s ambition to reduce absolute scope 3 GHG emissions by 30% by 2030 (base year 2021).
The partnership reflects both companies' alignment with the Science Based Target initiative and commitment to credible sustainability practices. The PCF methodology applied to entire SASOLWAX value chain is rigorously developed and independently reviewed to comply with ISO 14040, 14044, and 14067 standards, ensuring transparency and trust in environmental claims.
www.henkel.co.uk
SENSOR TECHNOLOGY LAUNCHES SGR523
Sensor Technology Ltd’s new SGR523 is poised to make a difference in applications requiring meticulous torque-angle analysis, setting a new benchmark in torque and angular position monitoring, according to the brand…
Sensor Technology Ltd has introduced the SGR523, a stateoftheart digital rotary torque sensor equipped with an integrated incremental angle encoder. This addition to the TorqSense SGR series “sets a new benchmark for precision in torque and angular position monitoring”, says the brand, suitable across various industrial applications.
The SGR523 employs noncontact strain gauge technology, eliminating the need for traditional slip rings and enhancing reliability. Its highresolution angle encoder delivers up to 10,000 pulses per revolution with an impressive resolution of 0.009°, making it ideal for applications requiring meticulous torqueangle analysis, such as mechanical testing, automated assembly and process control.
Key Features:
• Torque measurement range from 175 mNm to 20 Nm
• Accuracy of ±0.1%
• High mechanical overload capacity of 400%
• Overrange reading capability of 250%
• High digital sample rate of 4,000 samples per second
• Digital outputs: RS232 and USB (standard); CANbus and Ethernet (optional)
• Bidirectional angle and rotation count
• Speed measurement up to 9000 RPM
• Compatible with TorqView Advanced Torque Monitoring Software
• Lifetime warranty
”THE
SENSOR’S ABILITY TO MONITOR TORQUE AT SPECIFIC SHAFT ANGLES
The SGR523's advanced capabilities enable engineers to detect mechanical anomalies, such as rotational stiction or thread damage, by analysing torque versus angle plots. This dualparameter monitoring is crucial for quality assurance in manufacturing processes, including bottle cap tightening and bolt fastening.
Additionally, the sensor's ability to monitor torque at specific shaft angles aids in identifying potential issues in process control applications, thereby reducing production wastage. Its highresolution angle measurement also facilitates precise motion control, allowing for better management of inertia in motion platforms and improved safety in automated machinery.
The SGR523's design simplifies system architecture by combining torque and angle measurement into a single unit, reducing component count and enhancing system reliability. Its robust construction and advanced diagnostics, including BuiltIn Test (BIT) selfdiagnostics and shaft temperature monitoring, ensure consistent performance even in demanding environments.
For more information about the SGR523 and other torque measurement solutions, visit Sensor Technology Ltd's website.
www.sensors.co.uk
There’s no kitchen sink, but Snap-on’s general maintenance kit does include a whopping 256 pieces
SNAP-ON INDUSTRIAL’S NEW GENERAL MAINTENANCE KIT
International operator Snapon Industrial has unveiled a new ‘ultimate tool kit’ designed primarily for technicians work, on the road. The new 256piece General Maintenance Kit offers a comprehensive assortment of tools to arm technicians for repairs wherever the job takes them.
The kit, from Wisconsinheadquartered Snapon, is packed in a heavyduty road chest designed for use in the back of a van or truck. Chests are available in red, blue, or black and all come preassembled with tools in foam cutouts for efficient organisation, tool identification, inventory and storage.
The chest’s cover and front are hinged together for quick and easy access to all tools. Three friction hinges in the front cover keep it from slamming and allow technicians to hold it in an open position if desired. Piano hinges are made from stainless steel to resist rust from use in rugged environments.
Tools include:
• 14.4 Volt MicroLithium impact wrench and ratchet
• 8 Volt impact wrench
• 1/4", 3/8”, and 1/2” drive tools and sockets; 1/4" drive sockets are chrome; 3/8” drive sockets are impact rated
• Wrenches: combination, flare nut and adjustable
• Pliers: slip joint, angle nose, diagonal cutters, long nose locking, retaining ring and wire crimpers
Visitors to SIFER 2025 this June (2426) at Lille Grand Palais, France, will be able to see Snapon Industrial and its latest lines in person. Snapon Industrial will be exhibiting together with AMDP / OCETA on Stand 1129, with its ATC (Automated Tool Control) solution on show in particular, but with the firm also keen to chat with customers and visitors about its other lines and services, including torque, other Tool Control solutions, hand tools and more.
Snapon Industrial designs and supplies products and services to their customers, including hand & power tools, tool storage, tool control, information & management systems and other solutions for aviation & aerospace, government & military, rail, energy and education.
b2b.snapon.com
PLASTIC FIXINGS & FASTENERS
WEIGH THE DIFFERENCE WITH PLASTIC
From reducing weight and costs to improving durability and resistance, plastic fasteners are a smart alternative to traditional metal fasteners. These selling points have helped bring success over the past decades to Volt Industrial Plastics, located in Yellville, Arkansas. Mastering the art of producing and delivering precisionengineered plastic fasteners that provide a costsaving option to manufacturers across the globe, Volt’s customers have grown to rely and depend on these innovative, strong and reliable fasteners.
Why plastic?
1. Lightweight yet strong
One of the biggest advantages of plastic fasteners is their weight—or lack of it. Unlike metal fasteners, which can add unnecessary bulk, plastic fasteners offer high tensile strength while remaining lightweight. This makes them ideal for industries where reducing weight can improve performance, such as automotive and consumer electronics.
2. Corrosion-resistant
Rust and corrosion can be a major issue with metal fasteners, especially in humid or chemicalheavy environments. Plastic fasteners don’t rust, corrode or degrade over time, making them a longlasting solution for outdoor applications, marine use and harsh industrial settings.
3. Non-conductive & non-magnetic
For applications where electrical conductivity is a concern, plastic fasteners provide a safe, nonconductive solution. They’re also nonmagnetic, making them perfect for use in sensitive electronic equipment and other environments where metal interference can be a problem.
4. Cost-effective & customisable
Plastic fasteners are more affordable to produce and maintain than metal alternatives. Volt Industrial Plastics offers custom moulding options to create the exact fasteners in the colour of your choosing that you need for your project, ensuring a perfect fit and look for any application.
2025 new products
On Volt’s website you’ll find just under 100 new products that it has developed and now offers to its customers. Some of these include Hex Jam Nuts, Machine Hex, Phillips Fillister, Phillips Flat & Pan, Slotted Fillister, Slotted Binding, Slotted Round & Set, Shoulder Washers, Special Flat Washers and more.
In the fastpaced world of manufacturing, efficiency and performance are everything. When it comes to fasteners, the choice between metal and plastic can make a huge difference. Volt Industrial Plastics specialises in highquality plastic fasteners designed to outperform traditional metal alternatives in ways you might not expect.
Find out more about plastic fastening solution at the site: www.voltplastics.com
HUSUM WIND TO KICK-OFF WITH LANDMARK EXCURSION
TO mark the start of HUSUM WIND 2025, a special industry event will take place at sea on 15 September 2025, reportedly the largest excursion – in scope and concept – of its kind in the European wind market in the past 15 years.
The fullday offshore excursion will depart from Hamburg, offering industry professionals, exhibitors and companies the opportunity to experience firsthand the development of offshore wind energy utilisation over the past decade and a half.
The excursion, organised by Messe Husum & Congress in collaboration with the industry network WAB e.V. and the ferry operator FRS Helgoline, will include sites ranging from the first installations dating back to 2010 to the latest and largest generation of 15megawatt turbines.
During the fullday tour, 25 offshore projects operated by leading companies such as EnBW, EWE, Ørsted, RWE, Vattenfall, Ocean Breeze Energy, and the transmission system operator TenneT Offshore will be visited. In addition to facilities already in operation, the itinerary also includes projects currently under construction, such as Borkum Riffgrund 3 and EnBW He Dreiht. Expert commentary on board will provide indepth information on current technologies and processes. The highspeed catamaran "Halunder Jet", operated by FRS Helgoline, will depart Hamburg at 7 am on Monday 15 September, and return at around 7 pm. A full catering service will be provided for participants. In addition, the excursion offers a platform for professional exchange and networking in an exclusive setting at sea.
Installation inspiration: 25 offshore projects are on the itinerary
The tour fits neatly into a central topic for HUSUM WIND 2025 – offshore wind energy. The show is one of the leading platforms for the wind industry in the Germanspeaking region, showcasing innovations, projects and developments in both the onshore and offshore sectors. Particular focus is placed on the growing importance of offshore generation for the future of energy supply.
Offshore wind energy is considered an essential pillar of the energy transition in Germany and neighbouring markets. The installed 9,200 megawatts of capacity in the North and Baltic Seas currently make a significant contribution to climatefriendly electricity generation; numerous new projects are either planned or already under construction. To achieve the targeted climate goals and ensure energy security, Germany is aiming for a substantial expansion of offshore wind capacity.
Tour places are limited, with prices ranging from €259.99 to €349.
www.husumwind.com/en/tickets
Vessel of choice: The highspeed catamaran Halunder Jet, operated by FRS Helgoline, will be on duty
AGILE, REACTIVE & CAPABLE
Rapid’s range has broadened now that the firm is capable of handling harder to machine alloys
Managing Director Richard White tells Torque Direct how Rapid Industrial Fasteners has been stepping up a gear in terms of capability, with some significant investments made into the business to help it become an ever more complete supply solution…
Rapid Industrial Fasteners has been in the fastener business for decades, but its recent growth trajectory has been partially fuelled by the milestone decision made by the distributor to start manufacturing inhouse, back in 2019.
The firm hasn’t just been dabbling in fastener manufacture either. It’s growth in production, in part initially fuelled by Covid lockdowns, has seen it make some significant recent investments in the past 12 months. These have included more advanced machines, including those with more automated processes and those with the ability to handle difficult to machine materials.
“We’re growing as a business,” Managing Director Richard White tells Torque Magazine: “And we’re bringing in more advanced machines as we go.” Recent additions have included a four axis CNC machine, costing circa £200,000.
“We are stepping up a gear in terms of capability, expanding the product lines we can produce,” White explains. “These newer machines we can leave running, they don’t have to be manually operated. So, we can run them overnight and it’s opened the door to us taking on even bigger batch sizes.”
More advanced machines also mean that Rapid can now handle increasingly difficult materials, including harder to machine alloys like NIMONIC 80A. That, in turn, has opened up the range of industries Rapid can supply, manufacturing at a level required by the aviation and aerospace industries and
their famously stringent requirements. That roster of markets that Rapid currently serves includes oil and gas, the defence sector, water and flow control, solar, via merchants. and direct to original equipment manufacturers (OEMs).
A four axis CNC machine, circa £200,000 was one of the recent machine investments made by the firm
Rapid change
The pace has, appropriately, rarely let up since Rapid first stepped into production. The firm moved its machine shop and distribution centre much closer together in 2022 (now moments away, over the rail track) and it’s introduced an additional production unit to house the new machines. And following this most recent expansion, Rapid has 48 machines and a growing number of machinists – now at 12.
As well as giving it a fuller range of services to serve its customers, the changes have helped with that big modern challenge of recruitment: With its expanding manufacturing prowess, Rapid has become ever more eyecatching to prospective engineering and manufacturing talent.
Rapid manufactures products that go overseas as far as Mexico and in the US including Oklahoma and Tulsa. And, of course, products go out closer to home into Europe including Denmark, the Netherlands, France, Germany and others. The other arm of Rapid’s business – its distribution arm – also supplies products into Europe.
As distributor and producer, Rapid has a lot to offer, White says: “We aim to be the complete supply solution.”
Rapid has 1,000plus pallet locations and more than £2 million stock on the shelves, including plenty of standard products. Rapid can also run a schedule of products supply to end users if needed. Additionally, Rapid can compile packs to be used in assembly units or on the assembly lines. Helping with traceability and pace of production for end user customers, the kits see Rapid collect a number of parts as required.
In addition, the firm is close to manufacturer partners in Asia, China and India to fill out its capabilities further still.
Integrity & full support
Richard White is always keen to emphasise the integrity cornerstone of the business: “It’s about doing what we say, when we say. Like the name, we respond quickly. We can get products out to you, we can do double shifts when we need to…”
White isn’t keen on the term, viewing it a bit of a cliché, but the ‘complete solution’ phrase is nevertheless a good fit for Rapid, he says: “It’s genuinely what we are! It is very difficult, not everyone can do it. We are blessed with the team that we have, not least Operations Director Jason Hayfield. He manages the daytoday manufacturing, while I head up the distribution operation.”
Winning over the industry when you’re offering something
new can take a while, White admits: “It takes a few years to get over that initial cynicism you sometimes face. We started manufacturing and people maybe waited to see how we did.”
But the firm’s progress has been proof positive of its capabilities, he adds: “Now we’re at the next stage of development and are a few stages on. Our capabilities are up there with any of our competitors. We’ve bought the best you can – we’ve now got even higher spec machines – and that has moved things onto the next level.”
Rapid’s depth of machines now means there’s a wider range of jobs the firm can handle: “We’re able to do all volumes and we still have some manual machines for lower production runs. The advanced machines take longer to set up, but once that is done you can produce a lot of products. So, we’re flexible, and capable. We have a solution for whatever our customers need.”
“Not all orders are for 10,000 pieces, but we want to be able to support our customers and not cherry pick. We can look after all the supply and their supply needs. We offer local manufacturing, short lead times and fast prototypes.”
“2024 was an exciting year of investment. We have purchased eight new machines and we’ve increased our stock holding too. We’ve really ramped things up in the last 12 months.”
Rapid has also appointed a Marketing Manager too, Louise Manser, a measure of how the firm has grown and evolved: “You can’t do it all, you want specialists in key roles.”
White says: “We joined BIAFD (the British & Irish Association of Fastener Distributors) and we’ve signed up to the local Chamber of Commerce too. Things are always changing and legislation like CBAM looks to be one of the biggest challenges ahead. So, we try to stay informed and stay in front.
We hold large stocks for our customers and we can work to schedules for partner customers.
As part of Rapid’s programme of continual improvements, the firm is also investing in software, including a new system to benefit its Warehouse Management Systems (WMS) and B2B portal for customers.
“Following these big investments, we’re now letting things bed in. We want to fill the capacity that we have created. We invested heavily and we want to get the optimum benefit from it, for us and our customers.”
“We’re an asset to any supply chain. Rapid Industrial Fasteners is reactive, agile and capable of growth – we have control, volume and the agility to respond.” www.rapidfast.co.uk
Rapid is investing in its WMS systems as well as a B2B portal for customers
ROTOR CLIP SHARES WAVE SPRING KNOWLEDGE WITH ENGINEERS
Arming engineers with knowledge and resources is the intention behind Rotor Clip's freshly launched video...
Rotor Clip has released a new video to help engineers better understand wave springs and how they offer an alternative to traditional springs. In addition to saving space and weight, wave springs can reduce assembly height and streamline the number of components in an application. Now live on Rotor Clip’s website, this video breaks down the functions of wave springs.
A wave spring is a type of flat wire compression spring with a unique waveformlike structure. Unlike traditional coil springs that produce forces through torsion, wave springs generate forces through bending. This allows them to compress and expand while occupying up to 50% less axial space, providing engineers with more flexibility in their designs, says Rotor Clip.
“Many engineers are still defaulting to traditional coil springs, but this video shows why it’s worth taking a second look,” says Craig Slass, CoPresident of Rotor Clip. “Our goal is to make it easy to understand how wave springs work and how they can help solve space and weight challenges across industries.”
Rotor Clip offers a full range of wave spring configurations; each suited for specific applications from electric motors and fluid pumps to surgical tools and aerospace systems. Its wave springs reduce spring height and weight and can improve overall assembly function.
The brand offers a full range of wave spring configurations
• Multi-Turn Wave Springs: Provide the same force as coil springs but at half the height, maximising space and weight savings.
• Single-Turn Wave Springs: Commonly used for bearing preload and tolerance takeup.
• Nested Wave Springs: Increase load capacity in direct proportion to the number of turns, allowing for nearly unlimited force generation.
• Round-Wire Wave Springs: Ideal for generating heavy loads in tight spring cavities and are often compared to single Belleville washers or disc springs.
• Linear Wave Springs: Offer an excellent option for applications requiring preload in a straight groove or channel.
The new video is part of Rotor Clip’s ongoing effort to provide engineers with the knowledge and resources they need to design smarter and more efficient systems.
Updates for Kistler’s jBEAM Lab data analysis software means that efficient measurement data processing is now also available for NVH tests, set to aid development processes in the automotive industry, among others…
Kistler’s data analysis software jBEAM Lab has been updated to offer functions that enable even more efficient analyses without any programming effort. As a result, raw data can be used to create diagrams and spectrograms regardless of hardware. It can also be flexibly modified with filters and visualisation functions to maximise analytical capability, interactivity and resultdriven insights. What’s more, it now features special functions to support NVH tests (noise, vibration and harshness).
Development processes in aerospace, automotive and other sectors are not only becoming increasingly complex but are also accelerating. Timetomarket is crucial for manufacturers to succeed with new models and innovations to maintain their competitive edge. In challenging development environments in particular, data analysis software becomes a key factor to enable fast analysis and overcome development challenges.
“Analyse measurement data in just a few clicks”
The new version of the jBEAM Lab universal measurement data analysis software from Kistler combines speed with increased userfriendliness and interactivity. Diagrams, filters, calculations and more can be configured with draganddrop or just a few clicks and combined to create powerful analyses without having to write a single line of code. Jan Schnabel, jBEAM Product Manager at Kistler, says: “Whereas before, developers would have to write or program complicated scripts, for example in Python, they can now carry out and complete process steps with just a few clicks thanks to jBEAM – including for NVH tests.”
jBEAM Lab imports raw data from over 100 file formats, correlates it with audio and video data, and generates comprehensive visualiSations. The graphical processing offers a high degree of flexibility and interactivity: the data analysis software allows users to filter and flexibly combine data to create graphics, dynamically adapt workflows and directly simulate filters. Once analysis is complete, users have the option to generate reports automatically and precisely.
New functions specifically for
NVH tests
The new jBEAM from Kistler offers enhanced NVH functions specifically for aerospace applications. For example, manufacturers of reaction wheels for attitude determination and control systems (ADCS) on satellites need to carry out strict quality inspections during which they analyse microvibrations as part of their endofline tests, among other things. The comparison of key indicators such as harmonic orders, harmonic amplitudes, identification of imbalances and displacement of the structural resonance between different tests and wheels is decisive.
jBEAM’s automatic reporting function cuts the time required for postprocessing from around an hour per report to just a
Kistler offers complete measuring chains for NVH tests, modal analyses, and similar applications – from sensor through to software – including jBEAM measurement data analysis software for efficient post-processing
few seconds, says Kistler. The new functions for NVH tests were developed specifically for the aerospace industry, but can also be applied in many other fields. These include:
• Spectrogram and order analysis
• Octave analysis
• Simulation of analogue filters such as Bessel, Butterworth and Chebyshev filters
Schnabel continues: “jBEAM measurement data analysis software can be used as a flexible platform to automate the entire analysis workflow. The creation of spectrograms and order analysis, which was previously a relatively complex process made up of many individual steps, can now be carried out via draganddrop and with just a few clicks.”
www.kistler.com
The universal data analysis software jBEAM Lab from Kistler supports fast and flexible evaluation of all kinds of test data while at the same time eliminating the need for complicated programming and reducing development costs
THE CRITICAL ROLE OF FASTENERS IN ELECTRIC VEHICLE INNOVATION
The humble fastener plays a vital role in electric vehicle operation, from thermal management to energy efficiency and more. Optimas OE examines the part that fasteners play and how manufacturers can benefit from the right fasteners…
As the electric vehicle (EV) market continues its rapid expansion – with a projected CAGR of over 16% from 2025 to 2029 – manufacturers are facing new design and engineering challenges. Performance, range, safety and sustainability are all under the microscope. While batteries and drivetrains dominate the conversation, a less visible but equally critical component deserves closer attention: Fasteners.
From structural integrity to thermal management, the right fastener strategy can enhance vehicle performance, reduce weight, support energy efficiency and extend battery life. With EVs becoming increasingly complex, manufacturers must view fasteners as performance enablers.
Lightweighting and thermal management are some of the considerations
EV manufacturers need to have in mind when selecting fasteners
Here are six key fastener considerations that should be front and centre for EV manufacturers:
1. Strength and durability are fundamental EVs must withstand constant vibration, dynamic loads and hightorque environments. Fasteners used in structural and safetycritical areas need to meet stringent tolerance and fatigue resistance standards. Manufacturing techniques like cold forming are often employed to increase the material’s metallurgical strength and structural reliability. An engineered fastener can bear significant load (65–90% of its yield strength), ensuring longterm stability and minimising the risk of failure during operation.
2. Lightweighting drives performance
Batteries are heavy. To improve range and overall efficiency, every opportunity to reduce vehicle weight must be taken –including fasteners. Parts made from lightweight materials such as aluminium, magnesium, advanced highstrength steel (AHSS) or titanium help to offset battery mass, improving handling, acceleration and energy consumption. Even small weight savings at the component level can lead to measurable gains in battery performance and vehicle range.
3. Corrosion resistance is essential in real-world conditions EVs operate in harsh environments – exposed to moisture, salt, road chemicals and fluctuating temperatures. Fasteners must be made of corrosionresistant materials like stainless steel, titanium or coated aluminium. Surface treatments and plating finishes also play a critical role in preventing both standard and galvanic corrosion. Ignoring this aspect risks longterm durability and safety.
4. Thermal management starts with material choice
EVs generate considerable heat, but fasteners can support thermal dissipation. Materials like aluminium offer high thermal conductivity and can help spread heat away from sensitive areas. In other scenarios, thermal insulation is preferred to
”FASTENERS MADE FROM NON-FERROUS METALS SUCH AS ALUMINIUM, MAGNESIUM AND TITANIUM OFFER BENEFITS BEYOND JUST LIGHTWEIGHTING“
prevent heat transfer to temperaturesensitive components or to avoid condensation in areas with electrical systems. Selecting fasteners with the correct thermal profile is a key part of designing a safe and efficient thermal strategy.
5. Energy efficiency is influenced by fastener material and design
Fasteners made from nonferrous metals such as aluminium, magnesium and titanium offer benefits beyond just lightweighting. These materials are nonmagnetic and offer better compatibility with electric systems, reducing electromagnetic interference and contributing to overall energy efficiency. Design choices like thread geometry, torque control features and head configuration also affect installation energy and mechanical performance.
6. Sustainability in fastener production supports the broader EV mission
Manufacturers are increasingly expecting their suppliers to embrace sustainable practices, from material sourcing to production methods. Techniques like cold forming minimise waste and reduce the need for energyintensive machining. Additionally, waste from prototyping and testing can be recovered and reused, supporting a more sustainable manufacturing model.
FASTENERS AS STRATEGIC ENABLERS IN EV DESIGN
In a highly competitive and rapidly evolving market, every component decision matters. Fasteners may seem like small details, but their impact on performance, efficiency, safety and sustainability is significant. As EV projects continue to evolve, integrating fastener strategy early in the design process, ideally with the support of dedicated application engineers, can streamline assembly, reduce costs and improve the overall product.
As a global distributor and manufacturer of industrial fasteners, Optimas can help OEMs rethink their fastener strategy and elevate their products to ensure they stay ahead of the curve.
Contact Optimas today to see how its valueadded solutions can improve your efficiency and profitability today.
Optimas is a leading global industrial distributor and service provider specialising in fastening and supply chain solutions for manufacturers seeking to improve efficiency and profitability: "We take care of the details so customers can focus on manufacturing cuttingedge products – giving them an unparalleled competitive edge." optimas.com
RIVETS & RIVETING TECHNOLOGY
INNOVATIVE AND RELIABLE HIGH-PERFORMANCE FASTENERS
Used across a wide range of sectors, Rivit’s product ranges and solutions include battery-powered and hydro-pneumatic riveting tools, as well as monitoring systems and more…
In an everchanging production landscape, the Italian company Rivit has been long offering highperformance fastening solutions. Focusing on innovation and reliability, Rivit operates in strategic sectors such as automotive, railway, heavy carpentry and shipbuilding.
The new FASTENERS&TOOLS 11 catalogue is an intuitive and detailed technical guide offering a complete overview of the company's wide range of products. From advanced devices to monitoring tools, Rivit's solutions are designed to optimise industrial processes with precision and reliability.
Among the flagship products is the 700 Series of batterypowered riveting tools, designed to offer maximum flexibility and mobility. The RIV710 and RIV720 models are ideal for rivets up to 6.4 mm, while RIV730 and RIV740 handle threaded rivet nuts up to M12. Equipped with brushless motors and longlife batteries, these tools guarantee effective performance even in environments where a mains connection is impractical.
For even more demanding operations, the 400 Series hydropneumatic riveting tools offer high power on a wide range of materials. Their compact and ergonomic design makes them perfect for continuous use in demanding industrial environments.
When it comes to complex fastening applications, the RIV943 hydropneumatic riveting tool proves itself. Thanks to an upgraded motor, it offers dual adjustment (10 mm stroke and force up to 32,000 N), while the onestep mode allows the rivet nuts to be deformed and unscrewed in a single movement, significantly speeding up production cycles.
To further increase process reliability, Rivit has developed Controlriv GEN3, a stateoftheart electronic monitoring system. Designed for highprecision contexts such as the automotive industry, Controlriv GEN3 constantly monitors
Controlriv Gen3 is a process control for blind rivets, rivet nuts and lockbolts
compressed air pressure and alerts the operator in real time in case of anomalies in the application. Equipped with full connectivity (Ethernet/Profinet and WiFi/Bluetooth), it integrates seamlessly into smart production lines, ensuring consistent fixture quality and reduced downtime. This device can be used both in standalone mode and in clusters, and makes it possible to prevent and reduce faults and errors in fixing, thus reducing costs and optimising processes.
”CONTROLRIV GEN3 INTEGRATES SEAMLESSLY INTO SMART PRODUCTION LINES, ENSURING CONSISTENT FIXTURE QUALITY AND REDUCED DOWNTIME“
In addition to the wide range of references, Rivit is firmly committed to customer collaboration and customised technical support. Backed by 50 years of experience and a vision oriented towards the future, Rivit offers complete fastening solutions, designed to evolve with the needs of modern industry.
“In a manufacturing sector increasingly oriented towards efficient, digitised and sustainable processes, Rivit continues to be a reliable partner and a benchmark in the world of industrial fastening,” the firm says.
www.rivit.it
The RIV943 hydropneumatic riveting tool has an upgraded motor and offers dual adjustment
Rivit's Series 700 is the flagship range of battery tools, designed for maximum flexibility and mobility
“WE NEED TO CREATE OUR OWN SUSTAINABLE, PROFICIENT, SKILLED WORKFORCE, BEFORE WE CUT OFF THE CURRENT SUPPLY”
‘SKILLS EMERGENCY’ – NEEDS BUSINESS OVERHAUL
A PROMINENT expert in Engineering and Manufacturing skills has called for business to urgently overhaul UK skills provision to ensure there’s an adequate number of domestic professionals to sustain industrial operations.
The impending skills ‘emergency’ may mean that UK industry fails to meet current demand and fail to generate the growth and productivity that government yearns.
Responding to Prime Minister Keir Starmer’s announcement that skilled migration was going to be curbed for those that don’t have a degree, Ann Watson, CEO of Enginuity (formerly known as sector skills council Semta), said that a sudden reduction in visas for workers needed desperately by UK industry could prove disastrous if business does not react immediately.
“A massive uplift in UK skills training is now an urgent necessity, not just a laudable ambition,” says Ann. “This is fast becoming an emergency rather than just an acute problem.
“Industry is at a pivotal moment, if it is to maintain output, let alone grow as the Government is rightly fixated upon.”
Enginuity, known as the ‘sector connector’ will act as a catalyst between thousands of small and medium sized businesses
Above: Ann Watson, CEO of Enginuity
and government, to determine next steps.
“It seems that business will be expected to rollup its sleeves and make radical changes to skill people themselves. We will help them introduce best practice to their training regimes, and gear up throughput to try and ensure that this happens as quickly as possible.
“Much of our sector is already being strangled by a lack of skills in the pipeline and this might just finish them off. Many of the disciplines that are in most demand don’t need a degree level entrant – hence they won’t qualify for a visa.
“Even if we had people queuing up to enter vocational pathways to work, which often isn't the case, it would take years to get them to the sufficient level to hold their own in the workplace.
“Government is examining the possibility of reducing the duration and quality of apprenticeships, but it’s not the answer to a longterm problem. We need to create our own sustainable, proficient, skilled workforce, before we cut off the current supply.
“Hundreds of thousands of skilled workers are due to retire in the next five years which will only exacerbate the situation.”
In Scotland alone, more than a million additional workers are expected to be required in the next 10 years.
TFC EUROPE ACQUIRES VERUCON FASTENERS AND LOGISTICS GMBH
TFC EUROPE has further expanded its European footprint and operations by acquiring Verucon Fasteners and Logistics GmbH.
Located in Gotha, Germany, Verucon is an established specialist supplier of fasteners and services to a wide variety of manufacturing sectors throughout Germany and other markets worldwide. Including specialist CNC machining capabilities, this brings a valuable extension to TFC’s own capabilities in region and complements TFCs already strong position in Europe as a supplier of Vendor Managed Inventory services
for CParts with various high precision product solutions, such as Smalley Wave Springs and an extensive portfolio of Seals and ORings. Services include Kanban management of CParts, kitting and sourcing.
TFC Europe is an AFC Industries company, a provider of supply chain solutions, specialising in Vendor Managed Inventory (VMI), customengineered components, and valueadded services. In Europe, TFC locations extend to UK, Germany and Czech Republic serving customers across the continent and beyond.
FIVE TECHNOLOGICAL TRENDS REVOLUTIONISING THE AEROSPACE SECTOR
A focus on sustainability
The aerospace sector is undergoing a profound transformation driven by rapid advancements in digital technology. From artificial intelligence to robotics, these innovations are revolutionising the design, manufacture and operation of aircraft. Danny Peachey, Manager Great Yarmouth from HTL Group, a supplier of hydraulic torquing tools for several industries, has offered expert insight into five digital trends that are at the forefront of this revolution...
Sustainability is a significant consideration of more industries than just aerospace, but it is still hugely crucial to the progression of the sector moving into the future, particularly with the UK government confirming targets for 10% of all jet fuels in flights taking off on British soil to come from sustainable sources by 2030.
This places a huge onus on the sector to invest in strategies that push for improved sustainability across the board. One example is using technology to optimise and streamline processes for increased efficiency or investing in research and development (R&D) of biofuels that could reduce emissions.
AI, automation and robotics
Artificial intelligence (AI) is arguably the most significant digital trend impacting the aerospace sector. AI’s capacity to process vast amounts of data and learn from it is transforming numerous aspects of the industry. One of the primary applications of AI is in predictive maintenance. Traditional mainte
nance schedules are based on set intervals, which can lead to unnecessary downtime or unexpected failures. AI, however, enables predictive maintenance by analysing data from aircraft sensors in realtime. This allows for the identification of potential issues before they become critical, thereby improving safety and reducing costs.
”AI IS ARGUABLY THE MOST SIGNIFICANT DIGITAL TREND IMPACTING THE
AEROSPACE SECTOR. ONE OF ITS PRIMARY APPLICATIONS IS IN PREDICTIVE MAINTENANCE“
Robotics is another digital trend that is making significant inroads into the aerospace sector. In manufacturing, robots are being used for tasks that require high precision and consistency, such as drilling and fastening. These robots can operate continuously without fatigue, ensuring highquality production and reducing the time required to build aircraft.
In addition to manufacturing, robotics is playing a crucial role in maintenance and inspection. Drones equipped with cameras and sensors can inspect aircraft surfaces for damage, such as cracks or corrosion, much faster and more accurately than human inspectors. This not only improves aircraft safety but also reduces the downtime required for inspections.
Digitisation of old processes
In the aerospace sector, where safety, precision and efficiency are paramount, even the slightest improvement in processes can have significant implications. One of the most transformative digital trends in recent years has been the digitisation of old processes. Traditionally, aerospace operations relied heavily on
manual processes, paperwork and outdated systems. However, the advent of digital technologies has paved the way for the automation and streamlining of these processes, leading to improved productivity and cost savings.
Another area where digitisation is making waves is in the management of technical documentation and records. In the past, aerospace companies relied on paperbased manuals and records to document design specifications, maintenance procedures and regulatory compliance. However, the digitisation of these documents has made them more accessible, searchable and updatable. This not only improves the efficiency of operations but also ensures compliance with increasingly stringent regulatory requirements.
3D printing and additive manufacturing
Additive manufacturing, commonly known as 3D printing, is transforming the production of aerospace components. Traditional manufacturing methods, such as machining and casting, often involve substantial material waste and long lead times. Additive manufacturing, on the other hand, builds components layer by layer, which minimises waste and allows for the creation of complex geometries that would be challenging or impossible to achieve with conventional techniques.
In the aerospace industry, where weight reduction is crucial for fuel efficiency, 3D printing is particularly beneficial. It allows the production of lightweight components that don’t sacrifice strength, contributing to more efficient and environmentally friendly aircraft. 3D printing also allows for rapid prototyping and ondemand production of spare parts, reducing inventory costs and downtime. This uptake in the industry also aligns with the overall growth additive manufacturing has seen, with the predicted value being €19.23 billion (£16.29 billion) by 2026.
Incorporation of advanced satellite tech
Satellite technology has long played a crucial role in the aerospace sector, enabling communication, navigation and surveillance capabilities essential for safe and efficient flight operations. However, recent advancements in satellite technology are taking this role to new heights, with the incorporation of advanced satellite tech revolutionising various aspects of the aerospace industry.
One area where advanced satellite technology is making a significant impact is in air traffic management. With the everincreasing volume of air traffic, particularly in busy airspace regions, the need for more efficient and reliable air traffic control systems has never been greater. Advanced satellitebased systems, such as Automatic Dependent SurveillanceBroadcast (ADSB), provide realtime aircraft tracking and surveillance, enabling more precise and efficient air traffic management. This not only enhances safety but also reduces congestion and delays in the airspace.
Incorporating advanced satellite technology into the aerospace sector improves safety and efficiency and opens up new opportunities for innovation and growth. As satellite technology continues to evolve, its role in shaping the future of aerospace is set to become even more significant, ushering in a new era of connectivity, efficiency, and safety in air travel.
As these technologies continue to evolve, the future of aerospace looks set to soar to new heights. The integration of digital trends is proving indispensable, ensuring that the industry remains at the cutting edge of technological advancement and innovation.
www.htlgroup.com
BIRMINGHAM IS BRINGING IT!
Automechanika Birmingham is set to open in the first week of June and brings together hundreds of brands, products and industry professionals from across the automotive industry in a three-day event like no other in the UK.
Automechanika is heading to Birmingham once again. The event on the 3 – 5 June 2025 at the NEC, is an automotive trade show like no other in the UK. In 2025 it will bring together over 550 brands from more than 25 countries and 15,000 senior UK based visitors from across the automotive industry, for three days of networking, learning and opportunity to make deals.
The mammoth event will include over 50 product launches and 150 hours of informative training sessions across multiple aspects of the automotive industry. Spread across several halls,
visitors can get their hands on new products, test tools for themselves and get up close and personal with new technology in the interactive features areas. Demonstrations from industry experts will be held across three stages – Vehicle Detailing Live, Paint & Spray Live and Body Repair Live.
Hosted by Education Partner, The UK Detailing Academy, Vehicle Detailing Live will have practical demos and discuss the sector’s challenges and opportunities.
Fully operational and ventilated spray booths are the cornerstone of Paint & Spray Live. Sponsored by MasterFlo UK
and with sessions hosted by Wayne Beardmore, the latest products and techniques will be put through their paces in the test area during live demonstrations.
Body Repair Live showcases handson body repairs with the latest innovations and expert insight. Sponsored by Solera, the area will cover topics including corrosion protection, marketing, ADAS and more.
While visitors can see, touch and try new products, as well as fully test tools and technology in 13 interactive features areas, there will also be a 3day Innovation4Mobility conference where leaders can come together to debate and tackle the big industry challenges head on. Located in the Automotive Supply Chain Forum, Innovation4Mobility in association with SMMT will help shape the future of transportation as industry leaders and visionaries engage in discussions covering electrification, sustainability, autonomy, technology and more.
The Workshop Hub has a programme full of seminars encompassing advancements in the service, repair and maintenance sector. Topics include vehicle diagnostics and garage operations, among others.
The Aftermarket Hub presents industry trends and insights to help managers and owners plan for the future operations
of their aftermarket business. Experts will share advice on AI, EV repairs, tyre safety and other aftermarket opportunities. Awards for the best and brightest in the industry will also be held during the event – with two different awards ceremonies. The Automechanika Birmingham Garage Awards will be held on Wednesday, 4 June at 5.30pm and celebrate the best in the garage industry. New for 2025 is the Thirty Under 30 Awards programme which will be held on the opening day, June 3 at 3pm. Celebrating the next generation of rising stars in the industry, 30 finalists have been selected by an expert panel and will be honoured at the event.
Additional networking and social events being held over the three days include the National Paint Championships, Bodyshop Buzz Social and the Women in Automotive Network Drinks Reception. Keep an eye on the programme for details on these and other networking opportunities.
No matter what sector you are in, Automechanika is vital for industry professionals to visit. So, whether you’re in the Aftermarket Trade, an Aftermarket Service Provider, or part of the supply chain, there is something for everyone at the event. Tickets are free and can be ordered through the website.
“NO MATTER WHAT SECTOR YOU ARE IN, AUTOMECHANIKA IS VITAL FOR INDUSTRY PROFESSIONALS
MANUFACTURING SUPPLY CHAIN EVENT
SThis year’s Subcon features workshops, product demonstrations, presentations and roundtable discussions…
ubcon will return in June to the NEC in Birmingham, featur ing more than 170 UK and international suppliers, as well as a series of workshops and product demonstrations.
The exhibition, which will take place between 45 June, covers assembly work, CNC machining, metal fabrication, electronics and component parts. It connects manufacturing buyers with suppliers across all industry sectors, including aerospace, automotive, medical, defence and security.
At the event, visitors can attend live product demo sessions to check out future solutions for efficiencies, products, materials, and systems. For example, Paloma Turning Co Pvt Ltd, a precision engineering company specialising in CNC turned and machined components, will showcase its product ranges for the automotive and industrial engineering industries.
Other exhibitors include UK Electronics, Universal Fabrications and Axea UK.
Attendees will also have access to peertopeer roundtable discussion sessions and CPDaccredited workshop sessions. They can seek advice from subject experts on progressing professional development or company strategy, ask questions and share challenges and solutions with peers.
Subcon will feature a comprehensive seminar programme with presentations from industry experts. Topics covered in the event include current approaches to connected manufacturing, the role of data and AI for smarter manufacturing, robotics and intelligent automation, lean manufacturing and the transformation of processes, recruiting and nurturing young talents, and the evolution of additive manufacturing.
One of the panel discussions that might draw interest from the attendees will be Manufacturing Supply Chains Under Geopolitical Uncertainties, which will take place on 4 June. In this panel discussion, the chairperson and speakers will explore how geopolitical dynamics reshape supply chains for critical products, from semiconductors and pharmaceuticals to renewable energy technologies. By examining the risks and
opportunities emerging from global trade tensions, reshoring initiatives, and technological advancements, attendees can learn more about how firms can build resilience and adaptability in an increasingly volatile world.
In another presentation on 5 June, From Data to Decisions: How AI and Analytics are Transforming Manufacturing Supply Chains, the speaker will explore how manufacturers can harness the potential of their data to drive smarter decisions and unlock new performance levels. Attendees will discover how realtime analytics and AIpowered insights enable predictive supply chain management, improve demand forecasting, and mitigate risks before they disrupt operations.
With an impressive lineup of expert speakers from some of the world’s leading companies, including RollsRoyce, LEGO Group, Siemens, and Jaguar Land Rover (JLR), the Subcon conference promises to be an inspiring event for manufacturing professionals.
The number of attendees is expected to grow by 25% this year.
In addition, Subcon will also feature the Manufacturing Solutions Show Awards 2025, which is set to take place on 5 June.
The awards offer five categories including Startup of the Year, UK Manufacturing Partner of the Year, International Manufacturing Partner of the Year, Product Innovation of the Year and Outstanding Industry Contribution.
Torque Direct is for fastener, adhesive, coating and tool businesses promoting themselves directly to the engineering sector.
Torque Direct is sent to named decision makers throughout the UK, as well as reaching the inboxes of over 70,000 international engineers and decision makers around the world, in the following specific market sectors:
UPCOMING EVENTS CALENDAR
WE’VE GOT A LIST OF SOME OF THE UPCOMING EVENTS IN THE FASTENER TOOLS, ENGINEERING AND MANUFACTURING WORLDS ACROSS THE GLOBE THAT ARE SET TO WELCOME VISITORS IN 2025.
THE TRADE SHOWS AND EVENTS ARE THE PERFECT OPPORTUNITY TO DISCOVER WHAT’S NEW IN PRODUCTS, TECHNIQUES AND TECHNOLOGY AS WELL AS MAKE CONTACTS AND NETWORK WITH OTHERS IN THE INDUSTRY
