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A Potted-In Composite Insert is one of two basic styles of inserts used in honeycomb sandwich panels. These are commonly referred to as "Wall Panel Inserts" or "Floating Inserts" because they are widely used in aircraft walls and stowage bins to fasten panels to each other and to the aircraft structure.

High strength Torlon® Potted Inserts can be used anywhere a fastener is desired, particularly where blind holes that do not pass all the way through the panel are needed or where inserts must be "flush" with the panel skin. In other words, there are no flanges, like that of a press-fit / adhesive bonded insert, to be glued to the top and bottom skins of the panel.

Installation Video of the steps involved in installing a potted-in insert into a honeycomb panel.

High-Tech Potted-In Insert Installation Guide

Potted-in inserts provide a necessary attachment point within a honeycomb panel. To properly install thermoplastic Torlon® floating inserts or wall panel inserts, the following process guide is recommended.

Installing Thru-Hole Wall Panel Inserts

  1. Drill a hole through the host material.
  2. Prepare epoxy adhesives and load it into a glue gun.
  3. Peel off the paper backing from the installation tab.
  4. Align with the potting holes on the insert and apply pressure.
  5. The installation tab allows the epoxy to be injected into one side.
  6. Once the flow control veins are filled with epoxy, masking tape should be placed on the backside of the panel to ensure that excess epoxy does not extrude from the back of the panel.
  7. The thru-hole insert can then be installed into the host material.
  8. Insert epoxy into the insert’s vent holes.
  9. Once the adhesive dries, remove the installation tab from the front and the masking tape from the back.
  10. The thru-hole insert is now successfully potted-in and flush-mounted on both sides.

Installing a Blind Floating Wall Panel Insert

  1. Drill a hole through the host material.
  2. Prepare epoxy adhesives and load it into a glue gun.
  3. Peel off the paper backing from the installation tab.
  4. Align with the potting holes on the insert and apply pressure.
  5. The installation tab allows the epoxy to be injected into one side.
  6. The blind insert is then installed into the host material, since it is blind the insert does not pass through to the opposite side of the panel.
  7. Insert epoxy into the insert’s vent holes.
  8. Once the adhesive dries, remove the installation tab from the front and the masking tape from the back.
  9. The insert will drop below the surface of the panel, which is a primary function of the floating insert tab.
  10. The blind insert is now fully potted-in and ready for attachment.

Diagrams on How to Successfully Install Wall Panel Inserts & Floating Inserts

In the figure below, a hole is drilled into or through the panel and the potted-in insert is placed into the hole where the adhesive-backed installation tab keeps it from falling all the way into the hole. In fact, when using blind inserts, an insert length should be selected that does not allow the insert to touch the inner surface of the bottom skin.

A minimum of 0.040 inches clearance is recommended to allow the adhesive to flow under and around the insert. The unique flow-control veins on MM's potted inserts prevent air pockets from occurring during adhesive injection into the hole. Air pockets are common with "old style" metal inserts, as the adhesive simply finds the path of least resistance and exits through the opposite vent hole without having to fill the entire hole.

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Contact Marketing Masters for Proper Techniques on Installing Wall Panel & Floating Inserts Today

At Marketing Masters, we can provide tips on how to properly install potted inserts. For strong, non-corrosive, lightweight & easy to install composite clip nuts, and inserts, Contact us OR Request a Quote today.