Hybrid Fastener and Method of Making the Same

A method of producing a hybrid fastener, the method comprising:

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

A method of fastening items using a hybrid fastener, the method comprising:

• forming a metal sleeve as a singular piece;
• connecting the metal sleeve to a composite body via die mold forming:
• the composite body comprising a shank;
• a shoulder;
• and
• a tip;
• covering an outer surface of the tip with the metal sleeve, one end of the metal sleeve aligning flush with an end of the tip, and another end of the metal sleeve engaging the shoulder, a width of the tip varying along a length of the tip, the width tapering from a second end of the composite body to the shoulder of the composite body;
• and
• fastening a first item to a second item via the hybrid fastener.

A method of fabricating a composite fastener comprising quasi-isotropic properties, the method comprising:

• molding a resin body that comprises an elongate shaft that comprises:
• a first that comprises a head;
• a second end;
• a shoulder;
• a tip, the second end of the shaft comprising the tip and the tip comprising:
• a length;
• an outer surface comprising a taper radially along the length of the tip;
• and
• a metal sleeve configured as a singular piece
• connecting to the outer surface of the tip to the metal sleeve while die mold forming the resin body, the metal sleeve covering the outer surface of the tip, one end of the metal sleeve aligning flush with the end of the tip, another end of the metal sleeve engaging the shoulder, the tip and the metal sleeve each tapering radially outward in a direction away from the head, and the metal sleeve comprising:
• an outer surface of the metal sleeve comprising male threads;
• and
• an inner surface of the metal sleeve engaging, tapering, and substantially matching the taper of the outer surface of the tip, the outer surface of the tip and the inner surface of the metal sleeve interlocking and holding the metal sleeve on the shaft.