Xometry.pro
en – EU
Knowledge & Community
Search
K
Quote & source your parts
Europe Europe
English DeutschFrançaisItalianoEspañol
Türkiye Türkiye
English Türkçe
United Kingdom United Kingdom
English
Global Global
English
select
navigate
switch tabs
Esc close

Get Instant Quote

Use our Instant Quoting Engine to easily quote and source your parts online

Get a Quote
Back
 Profile
Menu
Materials Library
Manufacturing Stories & Cases
Articles
E-Books & Guides
Free Tools
Webinars
Free Courses
Community Discussions
Create Topic
Quote & Source Your Parts
Get a Quote

Edit topic

Home Xometry Community Industrial Design Fastener size choice for a through-hole in 4 mm anodized aluminum plate

Fastener size choice for a through-hole in 4 mm anodized aluminum plate

0
K
3

Hi!

 Designing a lightweight enclosure for a small UAV component, using 4 mm thick anodized aluminum sheets. For the assembly, I need to fasten this plate to a 3D-printed ABS bracket underneath, which acts as a support and needs to be removable. The bracket is tapped, and I’m trying to decide what screw size to use for the through-hole in the aluminum that allows solid clamping without too much play or risk of deforming the hole over repeated assemblies.

Would you size the hole just clearance for an M4, or would M3.5 make more sense considering the wall thickness and material combo? This will likely be assembled/disassembled a dozen times during maintenance.

Link copied
    • K

      Hi!

       Designing a lightweight enclosure for a small UAV component, using 4 mm thick anodized aluminum sheets. For the assembly, I need to fasten this plate to a 3D-printed ABS bracket underneath, which acts as a support and needs to be removable. The bracket is tapped, and I’m trying to decide what screw size to use for the through-hole in the aluminum that allows solid clamping without too much play or risk of deforming the hole over repeated assemblies.

      Would you size the hole just clearance for an M4, or would M3.5 make more sense considering the wall thickness and material combo? This will likely be assembled/disassembled a dozen times during maintenance.

      0
      Reply
    • E

      I’d use M4, especially. An M4 screw gives you a bit more strength and better load distribution during clamping, which helps prevent fretting or hole deformation over repeated cycles. You’ll want a standard clearance hole—around 4.3 mm—for the aluminum plate. Since ABS is relatively soft compared to aluminum, the extra thread engagement from the M4 will actually help avoid stripping the tapped holes over time. Plus, you’ve got decent material thickness in the plate to back it up.

      0
      Reply
      Link copied
    • K

      Would an M3.5 be a safer bet for weight savings?

      0
      Reply
      Link copied
      • e
        Kirk Jarvis

        Maybe if you were really pressed for grams, but in UAV work, reliability usually wins over a few grams. M3.5 screws are much also less common, which could complicate sourcing. M4 is a solid, standard choice with good longevity, and easier to find replacements if needed.

        If removability is a key factor, then I’d design to insert nuts or brass inserts into the pillars. The slight extra weight will be compensated by much better re-use characteristics.

        0
        Reply
        Link copied
Fastener size choice for a through-hole in 4 mm anodized aluminum plate
Your information:




Suggested Topics

Topic
Replies
Views
Activity
How to correctly specify standard and non-standard threads in a technical drawing?
Industrial Design
For a machined part that has both standard and non-standard thread types, what’s the best way to call out threads in the technical drawing? In particular, should I use thread callouts or full detail... read more
I
0
174
Oct 30
Drawing callout for tight tolerance over short bore length
Industrial Design
hi, I have an aluminum housing for a small gearbox where the bearing seats are, of course, critical. I need to hold tight tolerances on the ID and OD, but only over a short... read more
A
S
4
157
Oct 31
DMLS tolerances for screw holes and sealing surfaces
Industrial Design
Hi, I’m working on a small metal housing (around 120 × 80 × 40 mm) that will be 3D printed with DMLS for a sensor module. It needs threaded M3 screw holes and a... read more
C
M
4
208
Oct 28
Design challenge: rope-to-rope transfer in a small cylindrical coupling
Industrial Design
Hi, working now on a small-scale linear actuator project and need a compact coupling between two coaxial cylinders. Both are 44 mm in diameter, with the upper one hollow (22 mm inner Ø). The... read more
V
E
4
192
Oct 17
Compact linear slide – how to balance smooth travel with lateral stability
Industrial Design
hi!I’m working on a compact linear slide mechanism for a handheld inspection tool. The carriage rides between two vertical guide rails and has to remain laterally constrained while still moving smoothly along the axis.... read more
C
A
4
243
Oct 15

Edit topic