Here's a list of the most advanced mechanical attachment methods for materials, especially metals and composites, used across aerospace, automotive, construction, and electornics:
1. Cold Forged Mechanical Interlocks (e.g., NRS / GripMetal)
- How it works: Micro-hooks are forged into a metal surface, and then a second material (e.g., aluminum, composites, friction materials) is pressed in, creating a cold-weld-like interlock.
- Use cases: Brake pads, heat exchangers, battery plates, acoustic panels, mass timber beams, EZBlocks
- Advantages: No adhesives, resistant to temperature and moisture, permanent mechanical lock.
2. Friction Stir Welding (FSW) with Mechanical Interface
- Hybrid: Combines friction stir bonding with engineered surface texturing or inserts (e.g., dovetails or interlocking pins).
- Use cases: Aerospace fuselages, EV battery enclosures.
- Advantages: High strength, joins dissimilar metals like aluminum to copper or steel.
3. Clinching and Self-Pierce Riveting (SPR)
- How it works: Localized deformation joins layered sheets without pre-drilling. Often used where welding is not feasible.
- Use cases: Aluminum-steel joints in automotive bodies.
- Advanced variant: Hybrid SPR + adhesive bonding for enhanced durability.
4. Interference Fit + Formed Features
- Example: Press-fit bushings, studs, or dowels with knurled, splined, or barbed features.
- Upgrades: Incorporate micro-hooks or textured surfaces for added retention.
- Used in: Aerospace fasteners, EV battery structures, structural wood-to-metal joints.
5. Hook-and-Mesh Microstructure Systems
- Emerging field: Uses arrays of metal or polymer microhooks (like a metallic Velcro).
- Commercial example: GRIPMetal, nano Velcro, or interlocked surface textures via additive manufacturing.
- Applications: Lightweight panels, structural composites, wood connectors.
6. Micro-Locking Fasteners / Advanced Inserts
- How it works: Threadless fasteners or inserts that expand, deform, or lock into substrates.
- Technologies: Spiralock, helical inserts with biting teeth.
- Applications: Electronics, aerospace panels, precision robotics.
7. Additive-Manufactured Interlocks
- How it works: 3D-printed parts with designed-in mechanical grip patterns—hooks, barbs, dovetails—built into the mating surfaces.
- Use cases: Custom lattices, snap-fit assemblies for composites or lightweight foams.
- Advantage: No secondary hardware needed, complex geometries possible.
8. Metal Foam Expansion Locking
- How it works: Closed-cell metal foam expands within a cavity or rough surface, locking in place as it cures.
- Use case: Structural inserts for crash zones, battery modules.
- Key benefit: Lightweight + energy absorption + mechanical bond.
If you’re looking for extreme durability, corrosion resistance, or
zero-maintenance under stress, the cold-forged interlock with microhooks (NRS/GripMetal) remains the most resilient and environmentally durable option—especially when bonded to galvanized or stainless substrates.
