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.

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Table of Contents

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)
  • G90 Steel: .048″ – .074″ (.122mm-1.88mm)
  • 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. 

Holes up to 0.500″ can be selected for hardware installation. When selecting holes 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.

When combining hardware installation and bending, the minimum distance from hole center to bend line center varies based on material. Please refer to our material catalog for specifications. 

No hardware with acute bends

We do not allow hardware installation on parts with acute bends. Contact our support team for questions.

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.
  • 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

Start your first SendCutSend project today!

Upload your CAD design, or try one of our customizable part templates to get instant pricing on your custom laser cut parts. All delivered to your door in a matter of days.

We proudly use hardware by PEM

Flush stud, M8 x 1.25, .472" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild

Thread SizeM8 x 1.25
Hole size in sheet (+0.003/-.0.000).315″
Minimum sheet thickness0.094″
Maximum sheet thickness.347″
Fastener materialSteel
Minimum distance hole C/L to edge0.378″
Minimum distance between two of the same hardware (CL to CL).567″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Aluminum material ranges (5052, 6061, 7075)0.100″-0.250″
Steel material ranges (CRS, HRPO, HR)0.104″-0.250″

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We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild, G30

Thread Size4-40 x .250″
Hole size in sheet (+0.003/-.0.000).168″
Minimum sheet thickness0.040″
Maximum sheet thickness.125″
Fastener materialSteel
Minimum distance hole C/L to edge0.230″
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..345″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Aluminum material ranges (5052, 6061, 7075)0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)0.048″-0.119″

We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Passivated

Stainless Steel: 304, 316

Thread Size440
Hole size in sheet (+0.003/-.0.000).166″
Minimum sheet thickness0.04″
Maximum sheet thickness.125″
Fastener material400 Stainless Steel
Minimum distance hole C/L to edge0.230″
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. Example shown with x2 of the same hardware..313″
Recommended panel materialStainless Steel
Coating typePassivated
304 Stainless Steel material ranges0.048″-0.125″
316 Stainless Steel material ranges0.060″-0.125″