Hybrid Fastener and Method of Making the Same

A fastener, comprising:

• a resin body including an elongate shaft having first and second ends;
• a head on the first end of the shaft;
• a tip on the second end of the shaft, the tip having a length and an outer surface tapering radially along the length of the tip;
• and
• a metal sleeve sleeved over and substantially covering the tip,
• the metal sleeve including an outer surface provided with male threads, an inner surface engaging and tapered to substantially match the taper of the outer surface of the tip, the outer surface of the tip and the inner surface of the metal sleeve interlocking to hold the metal sleeve on the shaft.

A method of producing a hybrid fastener, comprising:

• forming a metal sleeve having an internal through-hole therein;
• inserting the metal sleeve in a mold cavity;
• and,
• flowing a mixture of a melted thermoplastic resin and fiber flakes into the mold cavity, including filling the internal tapered through hole with the mixture.