APPLICATION TECHNOLOGY
every time. By utilising multiple high energy cyclic pulses together with a high compression force for each weld they can guarantee maximum fusion occurs, all within a fully controlled environment. Each weld is very closely monitored during the production process to ensure all set parameters are met and the optimum weld is achieved, resulting in a low stress, crack-free crystalline structure to the finished weld. A standard measure used to assess the control and
consistency of the weld is the number of bigHeads per million that were shipped with a defective weld. The average PPM rate since 2009 has been 1.33ppm. To support this high level of consistency bigHead is committed to continuous improvement and Lean Manufacturing. Data is analysed to streamline operations and reduce inefficiency. This ensures the service to customers is accurate, responsive and flexible.
Automotive bigHeads are used in cabin panels, interior trim, external
cladding, bumpers, moulded panels, light clusters, seating, anchor points, and many other applications. They are used in many of the world’s leading automotive companies such as Aston Martin, Bentley, Lotus, McLaren, Ford, Audi, VW, Mercedes, Jaguar Land Rover and JCB, as well as numerous kit car manufacturers and enthusiasts. bigHead is a BMW approved supplier to Rolls Royce Motors. As the automotive market is investing particularly heavily
in lightweight materials, bigHead is continuing to see an extension of demand from supercars to premium and luxury cars as lightweight materials such as carbon fibre extend their penetration. Aston Martin is a good example of a super car application.
The carbon fibre diffusers on Aston Martins are attached with bigHead fasteners and a structural adhesive (pictured below). Discrete and very strong, the bigHead fasteners are surface bonded on the inside of the diffuser. Completely invisible they require no rivets or drill holes. Due to the unique design of the perforated ‘head’, the glue flows through the holes and locks the fastener into position, achieving high stability and strength. Bonded in position by the Tier 1 supplier to Aston Martin the diffuser is ready for final assembly.
carbon fibre and other composite materials in the most severe marine environments. For many years bigHeads have been found in many of the
world’s leading boats such as Sunseeker yachts, Lasers and RNLI lifeboats. bigHead has also seen an increase in the use of bonding as
an alternative to welding in marine environments as welding can lead to weakness through corrosion. Offshore oil and gas platforms for example have started to implement adhesive bonding as an effective alternative to welding.
Construction bigHeads are used to secure interior panels, exterior cladding,
moulded panels, light clusters, seating, anchor points, and in many other applications. bigHeads are particularly good for discretely fixing thin panels where traditional drilled fixings are incompatible. Product tests show that bigHead fasteners withstand very high loads. Computer design and the proliferation of new materials
have challenged traditional building fixing systems that relied on masonry and timber produced in large cross-section. Some buildings such as Cloud Nine in Spain use lightweight composite materials as cladding. In the picture below the curved cladding panels are held in position by bigHeads surface bonded on the inside of the panel.
Made in UK bigHead fasteners are made in the UK, at the factory in
Bournemouth, Dorset. This ensures total control of product and process quality and a flexible service to customers. It is many manufacturers’ experience that low cost imports and overseas copies can actually increase production costs, with inconsistent quality leading to costly re-work and dissatisfied customers. bigHead continues to invest in process improvement and
Marine bigHeads are used to secure cabin panels, engine room
insulation, interior furnishings, deck fixings, light clusters, and in many other applications. Made of 316 stainless steel, bigHeads are ideally suited to provide high load bearing fixings to GRP,
134 Fastener + Fixing Magazine • Issue 75 May 2012
Lean Manufacturing but also in innovation. bigHead is working with MAS, Bath University and UWE on several projects to ensure its product and designs solutions remain innovative and relevant. bigHead is also working with world leading partners in composites and adhesives, such as ITW Plexus and 3M, to ensure that customers receive the best guidance and ultimately the best solution to their fastening challenges.
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