Innovative Potted Insert for Sandwich Panels

An innovation driven by real industrial needs

Innovation is at the core of SECAM Fixing Solutions’ DNA, a specialist in screws and inserts for plastics, light alloys, and composite materials. In this context, SECAM teams developed a solution that is simpler, faster, and more cost-effective than traditional NAS inserts.

As early as 2012, development began in response to a request from a major player in high-performance composite materials. After a phase of prototyping and testing, the SECAMnida® insert was officially patented in 2016.

This approach reflects a company culture focused on customization and close client collaboration, with the objective of delivering solutions that are truly adapted to industrial requirements.

A potted insert optimized for sandwich materials

SECAMnida® is not just another potted insert for honeycomb sandwich panels. It is a fully engineered technology designed to optimize the entire fastening process. Its self-locking and reinforced thread, combined with an optimized design, ensures high mechanical performance and excellent positioning accuracy.

After crimping, a two-component adhesive can be injected, with filling precisely controlled thanks to a dedicated indicator. This approach secures the operation while significantly reducing the risk of defects and non-conformities.

A significant reduction in installation time

While NAS inserts typically require up to 7 separate operations (drilling, trimming, positioning, bonding, curing, removal of holding elements, finishing), along with a 24-hour curing time, SECAMnida® drastically simplifies the process.

With only 3 steps, installation can be completed in 2 minutes 30 seconds, and the panel becomes immediately ready for handling and further processing. This drastic reduction in process steps improves productivity while minimizing human error.

Precision, repeatability, and reduced non-quality costs

From a quality cost perspective, the benefits are particularly significant when geometric defects or incorrect installations are detected after bonding traditional NAS inserts. Once the adhesive has fully cured, rework becomes complex and costly.

Thanks to its specific design, SECAMnida® ensures a high level of installation repeatability and positioning accuracy, particularly in terms of flushness and coaxiality. This makes it a highly relevant solution for manufacturers looking to improve assembly reliability.

An excellent strength-to-weight ratio

Another major advantage of SECAMnida® is its weight. The insert is made from a high-performance aluminum alloy suitable for crimping deformation. This structure is reinforced with strengthened internal threads and a stainless steel threaded insert, achieving an optimal balance between mechanical strength and weight.

This characteristic directly addresses the current challenges of weight reduction in the transportation industry, where lowering energy consumption has become both a technical and economic priority.

A solution already integrated into aerospace applications

The innovation behind SECAMnida® quickly attracted the interest of major aerospace equipment manufacturers. After several years of collaboration, testing, and laboratory validation, the solution is now qualified and integrated into current production of business class and first-class seating.

The volumes involved already represent several hundred thousand inserts, demonstrating both the maturity of the technology and its relevance in highly demanding industrial environments.

A successful automation strategy with GEBE2

In 2019, during the Paris Air Show (Le Bourget), SECAM and GEBE2 initiated a strategic collaboration. GEBE2, aware of the challenges and costs associated with automating NAS-type insert installation, was looking for a reliable and cost-effective solution.

This partnership went beyond concept development to deliver a concrete solution: an all-in-one robotic end-effector capable of drilling, crimping, dispensing adhesive, and performing a 100% automated final inspection.

This industrial alliance now enables a fully automated solution for installing fasteners in all types of sandwich panels, including honeycomb structures and beyond.

Benefits of the automated solution

• Improved repeatability of insert installation operations
• Automated quality control
• Full traceability of all operations
• High flexibility and adaptability to complex part geometries
• Reduced cycle times
• Lower non-quality costs

An innovation opening new perspectives

The collaboration between SECAM and GEBE2 opens up strong future opportunities, particularly to meet the growing demands of the aerospace market and increasing automation requirements.

SECAM now aims to expand the SECAMnida® product range with new innovations, continuing to redefine fastening standards for sandwich materials.