Method for designing and fitting, via interference, an insert into an opening in a non-metallic material

A method for inserting an insert into a hole in a composite material made from a plurality of carbon fiber layers suspended in a resin matrix, the hole penetrating through the composite material, the method comprising:

• lowering a temperature of the insert to a reduced temperature at which a coefficient of thermal expansion of a material of the insert causes the insert to contract to a first perimeter;
• inserting the insert at the reduced temperature into the hole in the composite material;
• and
• permitting the temperature of the insert to increase from the reduced temperature to an operational temperature,
• wherein at the operational temperature, the coefficient of thermal expansion of the material of the insert causes the insert to expand to a second perimeter greater than the first perimeter so as to exert a radial force on walls of the hole so as to be retained within the composite material due to an interference between the insert and the composite material, the interference being such that structural load is transferred from the insert to the composite material and such that dislodging the insert at the operational temperature from the composite material results in damage to the composite material,
• wherein the insert is manufactured to within a typical tolerance of 0.0005″ from its desired dimension, the insert comprising a PEEK material enhanced by carbon fibers.