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Jan. 15, 2024
As electric vehicle manufacturers increase the use of lightweight aluminum battery housings, thin sheet metal, and modular battery structures, fastening systems must provide more than a simple threaded connection.
Engineers and procurement teams need to consider joint strength, material compatibility, corrosion resistance, sealing, installation access, vibration, production efficiency, and long-term serviceability.
Blind rivet nuts provide a practical threaded fastening solution when access to the rear side of the workpiece is restricted. They can be installed from one side of an aluminum battery enclosure, thin sheet metal panel, or enclosed profile, creating a permanent threaded connection for screws or bolts.
For EV battery housings and new energy vehicle components, the appropriate rivet nut should be selected according to the parent material, sheet thickness, load requirements, environmental conditions, sealing requirements, and installation process.
Juxin Fasteners provides blind rivet nuts, sealed rivet nuts, aluminum rivet nuts, stainless steel rivet nuts, and OEM fastening solutions for automotive, EV, battery, electrical, sheet metal, and industrial applications.
The "pull method" comprises Spin on, 1. Insert, 2—upset, 3. and Spinoff, 4. cycles.
Selection criteria for blind rivet nut Selecting the body.
Hexagonal body A hexagonal body in a hexagonal hole ensures the blind rivet nut has the best resistance to over-torque turning. |  |
Round body, knurled or plain For use where a hexagonal hole is not possible. The knurled version is preferred to the smooth, particularly for plastic or soft materials (aluminum, PA, SMC, etc.). |  |
Open-end This is the most common option due to its compact form and the free choice of screw length. |  |
Closed-end For all uses where no liquid is to be allowed to pass between the screw and the blind rivet nut. To form a pressure-tight seal between the blind rivet nut and the workpiece, we manufacture blind rivet nuts with a seal on the bodyside (see example on page 112). |  |
Hexagonal body, flat head "Advantages: 1. Very high turning resistance 2. Suitable for soft components (aluminum, plastic,...) 3. High crimping force 4. screw length can be varied (open end) 5. Splash-proof closed-ended)" |  |
EV battery packs commonly use aluminum alloy housings because of their combination of low weight, corrosion resistance, thermal performance, and manufacturability.
However, thin aluminum panels can present challenges when a threaded fastening point is required.
Direct tapping may provide insufficient thread engagement, while welding a nut can introduce heat, distortion, additional processing, and potential surface damage.
A blind rivet nut creates a mechanical threaded insert without requiring access to the rear side of the panel.
One-sided installation
Threaded connection in thin sheet metal
No welding heat-affected zone
Suitable for aluminum battery housings
Efficient installation in enclosed structures
Potential for sealed fastening configurations
Compatibility with automated installation processes
Serviceable screw connections
For high-volume EV production, the ability to install a threaded insert from one side can also simplify assembly-line design and automation.
There is no single blind rivet nut that is suitable for every battery enclosure.
The correct selection should begin with the joint design rather than the thread size alone.
The key parameters include:
Parent material
Sheet thickness
Required grip range
Hole diameter
Thread size
Required pull-out resistance
Required torque resistance
Corrosion environment
Sealing requirements
Installation equipment
Production volume
Service and maintenance requirements
The first parameter engineers should confirm is the material thickness.
Every blind rivet nut has a defined grip range, representing the thickness range in which the insert can be properly installed.
For EV battery housings, common parent materials include:
Aluminum sheet
Aluminum extrusion
Thin steel sheet
Composite panels
Engineering plastics
Molded battery enclosure components
The actual material thickness should be measured and compared with the manufacturer's specified grip range.
If the workpiece is outside the specified grip range, the rivet nut may not form the intended blind-side deformation.
This can lead to:
Insufficient clamping
Reduced pull-out resistance
Excessive deformation
Rotation during screw installation
Damage to the parent material
Inconsistent assembly performance
For complex battery enclosure assemblies, engineers should also consider the available installation space behind the panel.
The body geometry has a direct influence on rotation resistance, pull-out performance, installation requirements, and compatibility with the parent material.
A hexagonal body rivet nut is designed to engage with a corresponding hexagonal hole.
This configuration provides high resistance to rotation after installation and can be particularly useful where the joint is exposed to higher installation torque.
Typical applications include:
Aluminum battery housings
Automotive brackets
Electrical enclosures
Industrial equipment
Sheet metal assemblies
Hexagonal body rivet nuts are especially attractive when the design allows a controlled hexagonal hole.
Round-body blind rivet nuts are commonly used where a standard round hole is preferred.
They can simplify hole preparation and are widely used in general sheet metal applications.
For softer parent materials, engineers may consider knurled or mechanically engaging body designs to improve resistance to rotation.
Knurled rivet nuts have an external mechanical profile that increases engagement with the parent material.
They can be considered for:
Aluminum
Engineering plastics
Composite materials
Thin sheet metal
Soft materials
The correct configuration should be validated according to the material hardness, sheet thickness, hole diameter, and required joint performance.
The end configuration is another important selection factor for EV battery and enclosure applications.
Open-end rivet nuts are widely used because of their compact design and flexibility regarding mating screw length.
They are suitable for many general-purpose threaded fastening applications.
Typical uses include:
Brackets
Covers
Interior components
Electrical equipment
Sheet metal assemblies
Closed-end rivet nuts provide a closed rear end and can be considered where the application requires additional protection against fluid or contaminant passage through the fastener.
They are particularly relevant when the enclosure design includes environmental sealing requirements.
However, the closed-end design should not automatically be interpreted as a guarantee of enclosure-level waterproofing.
The final sealing performance depends on the complete joint, including:
Rivet nut design
Sealing element
Mating screw
Washer or gasket
Hole geometry
Installation parameters
Panel design
Seal compression
Assembly tolerances
For battery enclosure applications requiring a defined IP rating, the complete enclosure assembly must be validated through the appropriate sealing tests.
EV battery housings are often exposed to:
Water
Condensation
Road spray
Dust
Cleaning fluids
Temperature cycling
Vibration
Humidity
When a fastening point forms part of an environmental barrier, a sealed blind rivet nut can be considered.
A sealed rivet nut may incorporate a pre-installed sealing element around the body or head to reduce the potential path for moisture and contaminants through the fastening hole.
Integrated sealing
Reduced assembly steps
Consistent seal placement
Compatibility with high-volume production
Reduced risk of missing separate sealing components
For automated EV battery production, pre-installed sealing elements can also simplify feeding and installation processes.
Material selection is critical for EV battery enclosure applications.
The most common options include:
Carbon steel provides high mechanical strength and is widely used for industrial fastening applications.
Advantages include:
High strength
Good torque resistance
Cost efficiency
Wide availability
Protective surface treatments may be required depending on the environmental conditions.
Aluminum blind rivet nuts are an attractive option for lightweight assemblies.
Advantages include:
Low weight
Good corrosion resistance
Compatibility with aluminum structures
Reduced overall fastening weight
They can be particularly suitable for lightweight sheet metal and aluminum enclosure applications where the required mechanical performance can be achieved with aluminum.
Stainless Steel Blind Rivet Nuts
Stainless steel blind rivet nuts provide high corrosion resistance and are suitable for demanding environments.
They may be considered for applications involving:
High humidity
Water exposure
Corrosive environments
Outdoor equipment
Marine environments
Automotive applications requiring enhanced corrosion resistance
The higher strength and corrosion resistance of stainless steel can make it attractive for demanding fastening applications,
but material compatibility and galvanic corrosion should also be evaluated when used with aluminum components.
When an aluminum battery enclosure is combined with a dissimilar metal fastener, engineers should consider galvanic corrosion.
This is particularly important where the assembly may be exposed to moisture or conductive contaminants.
Material selection should therefore consider:
Parent material
Fastener material
Surface treatment
Environmental exposure
Electrical isolation
Moisture exposure
Required service life
Depending on the application, engineers may use compatible materials, coatings, isolation layers, or other corrosion-control measures.
For EV battery systems, the fastener should be evaluated as part of the complete material and corrosion-control strategy.
Some battery components use thin aluminum, plastics, composite materials, or hollow sections where conventional rivet nut deformation may not provide the required load distribution.
A slotted blind rivet nut can provide a larger blind-side bearing area during installation.
The slotted shank deforms into multiple sections behind the workpiece, distributing the clamping load over a larger area.
This configuration can be considered for:
Thin aluminum panels
Plastic battery components
Composite materials
Hollow sections
Lightweight equipment
Thin sheet metal assemblies
Larger bearing area
Improved load distribution
Reduced local stress concentration
Higher pull-out resistance in suitable materials
Better suitability for soft or thin substrates
Actual joint performance should be confirmed through application-specific testing.
For EV battery housing applications, two important mechanical characteristics are pull-out resistance and rotation resistance.
Pull-out resistance describes the ability of the installed rivet nut to resist being pulled through the parent material.
It depends on factors such as:
Parent material
Material thickness
Hole diameter
Rivet nut geometry
Grip range
Blind-side deformation
Installation force
Torque resistance describes the ability of the installed rivet nut to resist rotation when the mating screw is tightened.
Hexagonal bodies and other anti-rotation designs can improve resistance to turning.
Engineers should define the required torque and pull-out performance according to the actual joint design rather than selecting a fastener based only on nominal thread size.
EV battery manufacturing increasingly relies on controlled and automated assembly processes.
Blind rivet nuts can be installed using:
Manual tools
Pneumatic tools
Hydraulic tools
Battery-powered installation tools
Automated installation systems
For high-volume manufacturing, installation parameters should be controlled to ensure consistent blind-side deformation.
Typical process considerations include:
Mandrel engagement
Installation stroke
Installation force
Tool torque
Fastener orientation
Hole tolerance
Feed system compatibility
Inspection requirements
For automated production, the rivet nut design should also be evaluated for feeding, orientation, blow-feed, and installation compatibility.
Blind rivet nuts can be used in a range of EV battery and electrical assemblies.
Used to create threaded mounting points in aluminum enclosure panels and covers.
Used for brackets, covers, cable management, and auxiliary component mounting.
Used where lightweight panels require threaded attachment points for cooling-related components.
Sealed rivet nuts can be considered where fastening points are located within an environmental sealing boundary.
Rivet nuts can provide mounting points for:
Wiring harness brackets
Busbar-related components
Sensors
Control modules
Cable management systems
Protective covers
The final fastener specification should always be based on the component drawing and required performance.
Although EV battery housings are a major application, the same engineering principles apply to many industries.
For lightweight body components, brackets, interior assemblies, electrical components, and sheet metal structures.
For aluminum panels, equipment housings, interior components, electrical cabinets, and mounting brackets.
For thin-gauge metal panels where direct tapping or welding is impractical.
For control cabinets, switchgear, electronic housings, and power distribution equipment.
For thin sheet metal housings, equipment covers, brackets, and access panels.
For machine guards, access covers, control panels, equipment housings, and modular components.
For suitable non-critical sheet metal and equipment mounting applications where corrosion resistance and one-sided installation are required.
Before placing an OEM order, confirm the following specifications:
| Parameter | Information to Confirm |
|---|---|
| Thread | M4, M5, M6, M8, M10, M12 or other |
| Parent material | Aluminum, steel, plastic, composite, etc. |
| Sheet thickness | Actual material thickness |
| Grip range | Required minimum and maximum thickness |
| Body type | Round, hexagonal, knurled, slotted, etc. |
| Head style | Flat, reduced, countersunk, etc. |
| End type | Open-end or closed-end |
| Material | Carbon steel, aluminum, stainless steel, etc. |
| Surface treatment | According to corrosion requirements |
| Sealing | Standard or integrated sealing option |
| Installation | Manual, pneumatic, hydraulic, battery-powered, automated |
| Environment | Water, humidity, chemicals, temperature, vibration |
| Testing | Pull-out, torque, sealing, corrosion, or other requirements |
| Annual volume | Required production quantity |
| Packaging | Bulk, tray, bag, automated feeding, or custom packaging |
Providing this information allows the supplier to recommend the most appropriate blind rivet nut configuration for the application.
Juxin Fasteners supplies OEM blind rivet nuts and customized fastening solutions for international manufacturers.
Our engineering team can review customer drawings and application requirements covering:
Thread specifications
Material
Dimensions
Grip range
Body geometry
Head configuration
Sealing requirements
Surface treatment
Installation method
Packaging requirements
Quality inspection requirements
For automotive and EV programs, fastener selection can be evaluated together with the customer's battery housing design, parent material, production process, and environmental requirements.
This helps engineering and procurement teams move from a generic rivet nut specification to a production-ready fastening solution.
Juxin Fasteners provides industrial fastening solutions for manufacturers requiring reliable threaded connections in lightweight and enclosed assemblies.
We focus on the complete joint design rather than selecting a rivet nut by thread size alone.
Custom materials, dimensions, body designs, sealing configurations, coatings, and packaging can be developed according to customer requirements.
Our fastening solutions can support EV battery housings, battery modules, automotive components, electrical systems, and lightweight sheet metal assemblies.
Inspection requirements can include dimensional inspection, thread inspection, visual inspection, installation testing, pull-out testing, torque testing, and other application-specific requirements.
Juxin Fasteners works with international OEM manufacturers, engineering teams, purchasing departments, and industrial distributors.
Selecting a blind rivet nut for an EV battery housing requires the correct balance of mechanical performance, material compatibility, corrosion resistance, sealing, installation process, and production requirements.
If you are developing an EV battery enclosure, battery module, aluminum housing, electrical enclosure, or lightweight sheet metal assembly, send Juxin Fasteners the following information:
Product drawing or specification
Thread size
Parent material
Sheet thickness
Hole diameter
Required grip range
Sealing requirement
Installation method
Required quantity
Application environment
Our engineering team can review the application and recommend a suitable blind rivet nut, sealed rivet nut, aluminum rivet nut, stainless steel rivet nut, or customized OEM fastening solution.
Juxin Fasteners
OEM Industrial Fastening Solutions
Email: info@juxinfasteners.com
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