🔧 Threaded Insert Press - Open Source

A precision threaded insert press built from 70% 3D printed parts with minimal hardware components. Perfect for installing heat-set inserts in 3D printed parts with professional accuracy and consistency.

✨ Features

• 🖨️ 70% 3D Printable - Most components can be printed on any FDM printer
• 🔩 Minimal Hardware - Uses common, easy-to-find components
• ⚖️ Weight-Assisted - Gravity-powered for consistent pressure
• 🎯 High Precision - V-slot linear motion ensures straight insertion
• 🔥 Soldering Iron Compatible - Works with standard soldering irons
• 📏 Adjustable Height - 400mm vertical travel for various part sizes
• 💰 Cost-Effective - Build for ~$30-40 in materials
• 🔧 Easy Assembly - Simple step-by-step construction
• 🎨 Customizable - Two grip designs for different soldering iron types
• ♻️ Reusable - Designed for thousands of inserts

🎯 Perfect For

• Installing heat-set inserts (M2, M3, M4, M5)
• 3D printing projects requiring threaded holes
• Small production runs
• Maker spaces and workshops
• DIY enthusiasts
• Professional prototyping
• Consistent, repeatable results

🛠️ Hardware Requirements

Bill of Materials (BOM)

Aluminum Extrusion

• 1x 2040 V-Slot Extrusion 400mm

Fasteners

• 15x M5 × 30mm Button Head screws
• 13x M5 Nuts
• 10x M5 Washers

Motion Components

• 5x 608RS Bearings (skateboard bearings)

Belt

• 1x GT2 Timing Belt (~450mm length)

Tool (Not Included)

• 1x Soldering Iron (25-60W recommended)
  • Compatible with standard grip diameter: 15-20mm
  • Temperature controlled preferred

Required Tools for Assembly

• M5 Allen wrench (hex key)
• M5 nut wrench or adjustable wrench
• Scissors or belt cutter
• Optional: Calipers for belt length measurement

📚 3D Printed Parts

Parts List

All STL files are included in the repository. Print settings below are recommendations:

Part Name	Quantity	Infill	Supports	Notes
Base.stl	1	30%	No	Base mounting plate
Front Carriage.stl	1	40%	Yes	Main carriage
Rear Carriage.stl	1	40%	Yes	Weight carriage
Soldering Arm.stl	1	30%	No	Connects iron to carriage
Soldering Iron Grip Standard.stl	1	30%	No	Standard grip
Soldering Iron Grip.stl	1	30%	No	Alternative grip
Decentration Post.stl	1	30%	No	Belt tensioner
Bearings In.stl	5	20%	No	Bearing inner race
Bearings Out.stl	5	20%	No	Bearing outer race
Bearings H.stl	2	20%	No	Horizontal bearings
Spacer.stl	2	20%	No	Bearing spacers
Pulley Plate.stl	1	30%	No	Top bearing mount
Cover.stl	1	20%	No	Rear carriage cover
Weight Arm.stl	1	30%	No	Belt tensioning arm

Print Settings

Recommended Settings:

• Layer Height: 0.2mm (0.3mm for faster prints)
• Wall Count: 3-4 walls minimum
• Infill Pattern: Grid or Gyroid
• Material: PLA, PETG, or ABS
• Nozzle: 0.4mm standard

Quality Parts (Front/Rear Carriage):

• Layer Height: 0.2mm
• Infill: 40%
• Walls: 4
• Top/Bottom Layers: 5

🚀 Assembly Instructions

Overview

Total assembly time: 1-2 hours

The press assembles in three main sections:

1. Base and vertical rail
2. Front carriage (soldering iron mount)
3. Rear carriage (weight system)

---

Section 1: Base Assembly

Step 1 - Prepare Base Components

Required:

• 1x Base.stl
• 1x 2040 V-Slot Extrusion 400mm
• 2x M5 × 30mm Button Head screws
• 2x M5 Nuts

Instructions:

1. Insert M5 nuts into the slots on Base.stl
2. Position 2040 V-Slot extrusion vertically
3. Align mounting holes

Step 2 - Attach Base to Extrusion

Instructions:

1. Insert screws through Base.stl
2. Thread into T-slot nuts in the extrusion
3. Tighten until snug (don't overtighten)

✓ Checkpoint: Base should be firmly attached with extrusion standing vertically.

---

Section 2: Front Carriage Assembly

Step 3 - Gather Front Carriage Components

Required:

• 7x M5 × 30mm Button Head screws
• 7x M5 Nuts
• 3x 608RS Bearings
• 3x Bearings Out.stl
• 3x Bearings In.stl
• 3x Spacer.stl
• 1x Decentration Post.stl
• 1x Front Carriage.stl
• 1x Soldering Arm.stl
• 1x Soldering Iron Grip (Standard or alternative)

⚠️ Important: Test-fit your soldering iron in both grip designs before proceeding!

Step 4 - Assemble Bearing Units (Make 3)

For each bearing unit:

1. Slide Bearings In.stl onto M5 screw
2. Press 608RS bearing into Bearings Out.stl
   • Should be snug fit
   • Press evenly to avoid binding

Step 5 - Combine Bearing Components

Instructions:

1. Push Bearings Out.stl (with bearing) onto screw
2. Inner and outer bearing holders should sandwich the 608RS
3. Repeat for all 3 bearing assemblies

Step 6 - Add Spacers

Instructions:

1. Install Spacer.stl on top of 2 bearing assemblies
2. Leave one bearing assembly without spacer
3. Spacers prevent bearing binding during movement

Step 7 - Install Decentration Post

Instructions:

1. Thread Decentration Post.stl onto the last (non-spacer) screw
2. This component tensions the belt
3. Should rotate freely

Step 8 - Mount to Front Carriage

Critical Step - Pay Attention to Orientation!

Instructions:

1. Locate "FRONT" marking on Front Carriage.stl
2. Correct Orientation:
   • Bearings face INWARD (toward extrusion)
   • If bearings are facing up, "FRONT" should be upside down
3. Insert all screws through carriage
4. Tighten nuts on opposite side

✓ Checkpoint: All 3 bearings should face the same direction, aligned for V-slot.

Step 9 - Prepare Soldering Iron Grip

Instructions:

1. Insert 2x M5 screws into Soldering Iron Grip.stl
2. Don't tighten yet
3. Test-fit your soldering iron

Step 10 - Attach Soldering Arm

Instructions:

1. Place 2x M5 nuts in Soldering Arm.stl
2. Thread screws from grip into arm
3. Tighten to create rigid connection

Step 11 - Join Carriage and Arm

Instructions:

1. Align Soldering Arm with Front Carriage
2. Use remaining M5 screws and nuts
3. Ensure 90° angle between parts

Step 12 - Install Belt (Front End)

Instructions:

1. Cut GT2 belt to approximately 450mm
2. Thread one end through Base.stl belt clamp
3. Belt orientation: Teeth facing INWARD
4. Route belt over Soldering Arm
5. Secure with screw

✓ Checkpoint: Front carriage complete! Set aside carefully.

---

Section 3: Rear Carriage Assembly

Step 13 - Gather Rear Components

Required:

• 10x M5 Washers
• 3x M5 Nuts
• 3x M5 × 30mm Button Head screws (remaining)
• 3x 608RS Bearings (from bearing assemblies)
• 1x Rear Carriage.stl
• 1x Cover.stl
• 1x Weight Arm.stl

Instructions:

1. Assemble bearings identically to Front Carriage (Steps 4-7)
2. Mount to Rear Carriage.stl

Step 14 - Attach Belt (Rear End)

Instructions:

1. Measure remaining belt length (should be ~450mm total)
2. Cut if necessary
3. Thread through Weight Arm.stl slot
4. Belt orientation: Teeth facing INWARD
5. Clamp with Weight Arm against Rear Carriage
6. Secure with M5 nut

💡 Tip: Leave belt slightly loose for now - final tensioning in Step 20.

Step 15 - Add Washers for Weight

Instructions:

1. Stack washers on the 3 vertical screws
2. Number of washers depends on your soldering iron weight:
   • Light iron (25W): 8-10 washers
   • Medium iron (40W): 6-8 washers
   • Heavy iron (60W): 4-6 washers
3. Goal: Balance iron weight for smooth, controlled descent

💡 Tip: Start with more washers, test, and remove if needed.

Step 16 - Install Cover

Instructions:

1. Place Cover.stl over Rear Carriage
2. Align holes with screw posts
3. Cover protects belt mechanism

Step 17 - Secure with Nuts

Instructions:

1. Thread 2x M5 nuts onto screws
2. Tighten to secure cover
3. Don't overtighten - parts should not deform

Step 18 - Rear Assembly Complete

✓ Checkpoint: Rear carriage should have belt attached and weights installed.

---

Section 4: Final Assembly

Step 19 - Install Top Bearing Plate

Required:

• 2x Bearings H.stl
• 2x 608RS bearings (final 2)
• 1x Pulley Plate.stl
• 2x M5 × 30mm screws
• 2x M5 nuts

Instructions:

1. Press bearings into Bearings H.stl
2. Mount Pulley Plate.stl to top of 2040 extrusion
3. Secure with screws into T-slots
4. Install horizontal bearings
5. Thread belt through bearings
6. Slide both carriages onto extrusion

✓ Checkpoint: Both carriages should slide smoothly on V-slot.

Step 20 - Belt Tensioning and Final Adjustments

Instructions:

1. Tension Belt:

   • Rotate Decentration Post.stl to take up slack
   • Belt should be taut but not extremely tight
   • Both carriages should move smoothly together

2. Test Movement:

   • Lift front carriage - rear should descend
   • Lower front carriage - rear should rise
   • No binding or sticking

3. Adjust if Needed:

   • If belt sags: Tighten decentration post
   • If movement is rough: Loosen belt slightly
   • If carriages separate: Adjust belt alignment

4. Final Check:

   • All bearings rolling smoothly
   • No wobble in vertical axis
   • Belt tracking centered

✓ Final Checkpoint: Press should operate smoothly with balanced weight.

---

🎯 Usage Guide

Installing Threaded Inserts

Preparation

1. Heat Soldering Iron:

   • Set to 200-230°C for PLA
   • Set to 240-260°C for PETG/ABS
   • Allow 5 minutes to stabilize

2. Prepare 3D Printed Part:

   • Drill or print pilot hole slightly smaller than insert outer diameter
   • Clean any stringing or debris
   • Place part on stable, heat-resistant surface

3. Install Soldering Iron:

   • Slide iron into grip
   • Ensure tip points straight down
   • Tighten grip screws firmly

Installation Process

1. Position Insert:

   • Place threaded insert on pilot hole
   • Ensure insert is perpendicular to surface
   • Hold part steady

2. Lower Press:

   • Gently guide front carriage down
   • Soldering iron tip should contact insert top
   • Let weight of press do the work

3. Monitor Insertion:

   • Insert should melt into plastic smoothly
   • Stop when insert is flush or slightly below surface
   • Don't force - add heat if needed

4. Cool Down:

   • Lift press
   • Allow insert to cool 10-15 seconds
   • Don't disturb part during cooling

5. Test:

   • Try threading a screw
   • Should thread smoothly with no resistance

Tips for Best Results

Do's:

• ✅ Use consistent downward pressure
• ✅ Keep iron perpendicular to surface
• ✅ Let insert cool completely before testing
• ✅ Practice on scrap parts first
• ✅ Clean iron tip regularly

Don'ts:

• ❌ Rush the heating process
• ❌ Apply excessive force
• ❌ Move part while insert is hot
• ❌ Overheat (causes plastic deformation)
• ❌ Use undersized pilot holes

Troubleshooting

Insert Won't Go In

• Cause: Pilot hole too small
• Solution: Increase hole size by 0.1-0.2mm

Insert Goes In Crooked

• Cause: Uneven pressure or surface
• Solution: Ensure part is level, apply even pressure

Plastic Deforms Around Insert

• Cause: Temperature too high or too slow
• Solution: Reduce temperature 10-20°C, work faster

Insert Spins in Hole

• Cause: Hole too large or not hot enough
• Solution: Use smaller hole or increase temperature

⚙️ Maintenance

Regular Maintenance

After Every 50 Inserts:

• Clean soldering iron tip
• Check belt tension
• Inspect bearings for smooth operation

Monthly:

• Lubricate bearings with light machine oil
• Check all screws for tightness
• Clean V-slot rails with dry cloth

As Needed:

• Replace worn bearings (rough/noisy operation)
• Adjust belt tension (stretches over time)
• Replace belt if damaged or frayed

Common Issues

Carriage Binding

Symptoms: Rough movement, sticking Causes:

• Debris in V-slot
• Over-tightened bearings
• Misaligned bearings

Solutions:

1. Clean V-slot thoroughly
2. Check bearing tightness (should spin freely)
3. Verify bearing alignment

Belt Slipping

Symptoms: Carriages don't move together Causes:

• Belt too loose
• Belt teeth damaged
• Decentration post loose

Solutions:

1. Tighten via decentration post
2. Inspect belt for damage
3. Replace belt if necessary

📊 Performance Specifications

Capabilities

• Maximum Part Height: 350mm
• Insert Sizes: M2, M3, M4, M5 (with appropriate tips)
• Precision: ±0.5mm alignment
• Cycle Time: ~10-15 seconds per insert
• Daily Capacity: 200+ inserts
• Operating Temperature: 150-300°C (iron dependent)

Build Stats

• Print Time: 15-20 hours total
• Print Cost: $8-12 (PLA filament)
• Hardware Cost: $25-35
• Total Cost: $35-50
• Assembly Time: 1-2 hours
• Skill Level: Intermediate

🔄 Customization & Modifications

Grip Modifications

Two grip designs included:

• Soldering Iron Grip Standard.stl - For 15-18mm diameter irons
• Soldering Iron Grip.stl - For 18-20mm diameter irons

Custom grip:

1. Measure your iron's grip diameter
2. Modify STL in CAD software
3. Adjust inner diameter to your iron + 0.5mm clearance

Height Adjustment

To change vertical travel:

1. Replace 2040 extrusion with different length:
   • 300mm for compact build
   • 500mm for larger parts
2. Adjust belt length proportionally

Weight System

Customize pressure:

• More washers: Slower descent, gentler insertion
• Fewer washers: Faster descent, more force
• Add custom weights: 3D print weight holders

🤝 Contributing

Contributions welcome! Here's how you can help:

Ways to Contribute

1. Design Improvements

   • Submit modified STL files
   • Create alternative grip designs
   • Optimize for different printers

2. Documentation

   • Add photos/videos of your build
   • Translate to other languages
   • Share tips and tricks

3. Testing

   • Test with different insert sizes
   • Try various materials (Nylon, ASA, etc.)
   • Report compatibility issues

4. Feature Requests

   • Suggest new features
   • Request specialized adapters
   • Propose alternate designs

Submission Process

git checkout -b feature/YourFeature
git commit -m 'Add YourFeature'
git push origin feature/YourFeature

Then open a Pull Request!

📝 License

This project is licensed under the MIT License - see the LICENSE file for details.

You are free to:

• ✅ Use for personal or commercial projects
• ✅ Modify and redistribute
• ✅ Sell prints or kits
• ✅ Create derivatives

Attribution appreciated but not required!

👤 Author

HexLions

Just a typical nerd who likes making things

• GitHub: @HexLions
• Project Link: https://github.com/HexLions/Threaded-Insert-Press-Open-source

🙏 Acknowledgments

• V-slot extrusion system for smooth linear motion
• 608 bearing standard for ubiquitous availability
• GT2 belt system for reliable power transmission
• All makers who inspired this design
• Community feedback for improvements

💬 Support & Community

• Issues: Found a problem? Report it
• Discussions: Questions? Ask here
• Pull Requests: Improvements welcome!

📚 Additional Resources

Recommended Reading

• Heat-Set Inserts Guide - CNC Kitchen
• Best Practices for Inserts - YouTube Tutorial
• Insert Selection Guide - McMaster-Carr

Where to Buy Components

• Extrusion: OpenBuilds, Amazon
• Bearings: Local hardware store, Amazon, AliExpress
• Belt: Amazon GT2 Belt
• Fasteners: McMaster-Carr, local hardware store

⭐ Star History

If you find this project useful, please consider giving it a star! ⭐

It helps others discover this tool and motivates continued development.

---

Made with ❤️ for the Maker Community

Happy Building! 🔧