3 Million Joints, Zero Cracked Bosses: Precision Fastening at Global Scale

How do you guarantee assembly reliability for 3 million joints across two continents, without risking a single cracked thermoplastic boss?

When a world-class leader in Intense Pulsed Light (IPL) technology developed their "Smooth" handheld device, the fastening requirement was about more than just "buying a screw."

The challenge was precision at scale. The device houses delicate PCBs and high-capacity batteries within a sleek, ergonomic shell. The fastening solution had to provide significant clamp force for durability yet be gentle enough to avoid stressing the thermoplastic bosses during high-speed automated assembly.

With production split between South Wales and China, repeatability was non-negotiable.

 

The Solution: The EJOT PT®

EJOT’s application engineers specified the EJOT PT® (WN1452). As the original pioneer of the PT® screw, EJOT developed this technology as the first dedicated specialist for thermoplastics. While it has since spawned a series of industry-changing variants, such as the DELTA PT® and EVO PT®, the original PT® continues to perform on its own as a benchmark for reliability. Its 30° thread angle is designed to reduce radial expansion, allowing for thinner boss designs without the risk of bursting.

Data-Driven Assembly To ensure a "zero-defect" output, we collaborated with Deprag—a global leader in high-precision industrial screwdriving and automation. By utilising Deprag’s sophisticated torque-monitoring technology, our team was able to map the perfect "signature" for each joint.

The data spoke for itself: digital torque curves confirmed a stable, repeatable drive cycle peaking at a precise 0.250 Nm. This level of control ensures every one of the 3 million screws installed annually reaches its target clamp load without fail.

 

The Outcome:

• Reliability at Scale: 3 million screws supplied annually to support global demand.
• Technical Excellence: Optimised 30° thread geometry minimises substrate stress.
• Process Control: Collaboration with Deprag achieved a consistent 0.250 Nm finish.
• Economic Efficiency: A high-performance fastening package delivered for approximately £30k per year.

By choosing EJOT, this technology leader secured more than just a component; they secured a robust, global manufacturing process.