Heat-Set Insert Straightener and Flattener

--Now Customizable for Different Metal Discs and Cylinders--

A simple tool for finishing brass heat-set threaded inserts. The tool is made by printing the model and installing a steel disc or cylinder into one end to create a metal face. The model is parametric, allowing customization for a variety of disc and cylinder sizes.

How to Use This Tool

Use a soldering iron to press the threaded insert until it is almost flush with the surface of your plastic part. Then use the metal face of this tool to press the threaded insert fully flush. This straightens and fully seats the insert while also flattening the surrounding plastic for a clean, professional-looking result.

Parts and Assembly

Insert your selected metal disc or cylinder to or into the end of the tool. The first supplied print profile is designed for a 13 mm × 1 mm steel disc from Amazon (here).  This option will require some type of adhesive such as superglue or epoxy.  The second print profile is designed for a 10 × 15 mm steel cylindrical dowel pin (here) that is pressed into the opening at the end of the tool.  You may be able to use other cylindrical or disc-shaped parts you already have on hand (see Customization below).  For example, you could probably use disc-shaped or cylindrical magnets. 

In the supplied print profiles, I made the working end of the tool effectively solid by specifying 75 top shell layers. This increases the thermal mass and helps prevent the plastic from overheating.

PETG seems to work well, at least for installing a few inserts at a time. For higher-volume use, you may want to step up to ABS or ABS-GF.

Customization

You can customize this model (using the Customize button) to accommodate different sizes of metal discs or cylinders. Customization allows you to specify the depth and inner diameter of the opening at the end of the tool, to accept any metal disc/cylinder.  I suggest adding around 0.2mm clearance to the inner diameter for a reasonably tight fit.  You can also customize the overall length of the tool and the thickness of the wall surrounding the disc/cylinder.  If you come up with a good configuration, please post pictures and a link to your metal insert, and feel free to upload your corresponding print profile!