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Guidelines for Hardware Insertion

We’ve got you covered when it comes to hardware insertion in your laser or waterjet cut metal parts. With a variety of hardware options available, it’s important to make sure that your parts work within the guidelines to ensure a successful fit.

SendCutSend is proud to use PEM(R) hardware.

Pricing and Order Information

Hardware insertion will add a $9 minimum to your cart total, and per-hole pricing will depend on the fastener selected and quantity.

When planning to place your order, keep in mind that hardware installation adds 1-3 business days to our normal processing times. Check out our Lead Times page for more information.

Materials Available for Hardware

We currently offer five materials in a variety of thicknesses for hardware installation:

5052 Aluminum: 0.040”-0.500” (1mm-12.7mm)
6061 Aluminum: 0.040”-0.500” (1mm-12.7mm)
7075 Aluminum: 0.125”-0.250” (3.17mm-6.35mm)
G30 Steel: .048″ – .059″ (.122mm-1.5mm)
Mild Steel: .048”-.500” (1.22mm-12.7mm)

General Geometry Requirements

All parts that have hardware installation included will need to meet certain size requirements in order to be manufactured correctly:

Min Part Size: 1” x 1.5”
Max Part Size: 36” x 46”

These are general size requirements for hardware insertion. Check the hardware catalog for each type of hardware below before submitting your order to make sure your parts meet all specifications.

When selecting your hole operations for the desired hardware in your design, we will automatically resize the hole to the required size based on the hardware selected.

Please keep in mind that because they will resize, you will need to verify you have adequate clearance to other features and edges of the material.

Hardware Options

Press Fit Nuts

Press fit nuts are internally threaded with a knurled outer diameter. Lightweight, simple, and able to withstand high pressure and high torque, press fit nuts are often found in flooring and aircraft applications.

Press fit nuts provide load-carrying threads in metal sheets that are too thin to be tapped.

Press Fit Standoffs

Used to stand parts of an assembly off of each other, press fit or self-clinching standoffs have a wide range of applications. They provide secure fastening for delicate parts, with electrical components being the most widely used in conjunction with press fit standoffs. Press fit standoffs provide a threaded fastener that delivers uniform spacing between parts.

Self-Clinching Studs

Also known as press fit studs, self-clinching studs are designed to be a permanent fastener in your assembly. Made to withstand high torque, stress, and weight environments, studs can be used in dozens of applications to increase the strength and longevity of your part.

Studs are typically used when it is inconvenient or impossible to access one side of a threaded joint or when there is not enough clearance around the joint to have a traditional nut/bolt on the material surface.

Flush Head Standoffs and Studs

Though our standoffs and studs are technically flush, they may be raised .015″ depending on your material selections

How to Add Hardware Installation to Your Order

When you have confirmed your part meets our geometry requirements and you’ve uploaded the file to our app, walk through the normal order process and select “Add Hole Operations.”

You’ll see a list of hole options which you can add hardware to, as well as a link to our catalog of hardware options. Select your desired hardware and size, and you’ll see it show up on the 3D preview of your part. Make sure the hardware is placed on the correct face (top or bottom). Click “Add to Cart” and the hardware will be included in your order.

File Setup

If after reading these guidelines you’ve found you need to make some changes to your part design, check out our tutorials for designing and preparing your files in Illustrator, Inkscape, and Fusion 360.

What to Expect

Visible tooling marks
Beware scratching and marking on anodized or plated parts
Hardware should only be used for its intended purpose
- Shearing, splitting, warping may occur otherwise
Improper use of hardware can result in failure.
- For information on design requirements visit the hardware catalog.
Hardware is installed after anodizing and plating
Hardware is installed before powder coating
Parts with powder coating will have hardware capped/plugged

Pre-flight Checklist

File is a two-dimensional vector format file.
All holes and cutouts are at least 50% material thickness for laser cut parts
All holes and cutouts are no less than 0.070” for most waterjet cut parts
All holes and cutouts are no less than 0.125” for all CNC routed parts
File is built at a 1:1 scale, preferably in inch or mm units
All objects are on the same layer
All stray points, duplicate lines, empty objects and text areas have been removed
No shapes have open contours
All shapes have been united, combined or merged
All text has been converted to outlines or paths
Cut-out text (reversed text) has bridges or has been stencilized

Hardware Resources

Hardware Catalog

Drill Size Reference Chart

Hardware Posts

Upload your CAD design or use our parts builder and get a free instant quote on your custom laser cut parts, all delivered to your door in a matter of days.

SKU	FH-M8-12
Thread Size	M8 x 1.25
Hole size in sheet (+0.003/-.0.000)	.315″
Minimum sheet thickness	0.94″
Maximum sheet thickness	.347″
Fastener material	Steel
Minimum distance hole C/L to edge	0.378″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole.	.535″
Recommended panel material	Steel/Aluminum
Coating type	Zinc
Length	.472″
Aluminum material ranges (5052, 6061, 7075)	0.100″-0.250″
Steel material ranges (CRS, HRPO, HR)	0.104″-0.250″

SKU	SO-440-8
Thread Size	4-40 x .250″
Hole size in sheet (+0.003/-.0.000)	.168″
Minimum sheet thickness	0.040″
Maximum sheet thickness	.125″
Fastener material	Steel
Minimum distance hole C/L to edge	0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole.	.314″
Recommended panel material	Steel/Aluminum
Coating type	Zinc
Length	.250″
Aluminum material ranges (5052, 6061, 7075)	0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)	0.048″-0.119″

Guidelines for Hardware Insertion

We’ve got you covered when it comes to hardware insertion in your laser or waterjet cut metal parts. With a variety of hardware options available, it’s important to make sure that your parts work within the guidelines to ensure a successful fit.

Table of Contents

Pricing and Order Information

Materials Available for Hardware

General Geometry Requirements