Abstract: A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool, operating the tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, and switching the automatic tool from the first setting to a second setting in response to a controller analyzing axial acceleration data of the FDS. The first setting is configured to rotate the FDS at a first rotational speed and to apply a first axial feed force. The first setting is further configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force. The second rotational speed is less than the first rotational speed.

Abstract: A method of installing a flow drill screw (FDS) into a substrate includes engaging the FDS with an automatic tool, operating the tool at a first setting to drive the FDS into the substrate by causing flow of the substrate to permit the FDS to penetrate the substrate, and switching the automatic tool from the first setting to a second setting in response to a controller analyzing axial acceleration data of the FDS. The first setting is configured to rotate the FDS at a first rotational speed and to apply a first axial feed force. The first setting is further configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The second setting is configured to rotate the FDS at a second rotational speed and to apply a second axial feed force. The second rotational speed is less than the first rotational speed.

Abstract: A screw includes a head portion, an externally threaded shank extending from the head portion, the externally threaded shank having an external surface, and a flow-hole-forming tip disposed at a distal end portion of the externally threaded shank. The flow-hole-forming tip includes a radiused lower zone having an external surface tangent to the external surface of the externally threaded shank, a conical middle zone having an external surface tangent to the external surface of the radiused lower zone, the conical middle zone defining a vertex angle, and a radiused distal end zone having an external surface tangent to the external surface of the conical middle zone. The flow-hole-forming tip includes a width of the flow-hole-forming tip is greater than a length of the flow-hole-forming tip and/or the vertex angle is greater than or equal to 90 degrees.

Abstract: A method includes operating an automatic tool at a first setting to drive a flow drill screw (FDS) into a substrate. The first setting is configured to rotate the FDS at a first rotational speed and apply a first axial feed force. The first setting is configured to cause flow of the substrate to permit the FDS to penetrate the substrate. The method includes detecting a predetermined first trigger condition including at least one of a depth gradient and a depth and switching the tool from the first setting to a second setting in response to a predetermined second trigger condition including at least one of a predetermined axial feed distance after detecting the first trigger condition and a predetermined time delay after detecting the first trigger condition. The second setting is configured to rotate the FDS at a lower rotational speed and apply a lower axial feed force.

Abstract: A tow hook includes a monolithic additively manufactured side wall defining a vehicle attachment member, a hollow main body extending from the vehicle attachment member, and a hollow towing member extending from the hollow main body. The vehicle attachment member is configured to rigidly attached to a vehicle and the hollow towing member is configured to securely attach to a towing machine such that the vehicle is towable via the tow hook. The vehicle attachment member can be a threaded shaft with a bore extending along a length of the threaded shaft. The side includes a chamfered plurality of apertures extending from an inner surface of the side wall to an outer surface of the side wall, and having with an inner dimension along a length direction of the hollow main body greater than an inner dimension along a circumferential direction of the hollow main body.

Abstract: A screw includes a head portion, an externally threaded shank extending from the head portion, the externally threaded shank having an external surface, and a flow-hole-forming tip disposed at a distal end portion of the externally threaded shank. The flow-hole-forming tip includes a radiused lower zone having an external surface tangent to the external surface of the externally threaded shank, a conical middle zone having an external surface tangent to the external surface of the radiused lower zone, the conical middle zone defining a vertex angle, and a radiused distal end zone having an external surface tangent to the external surface of the conical middle zone. The flow-hole-forming tip includes a width of the flow-hole-forming tip is greater than a length of the flow-hole-forming tip and/or the vertex angle is greater than or equal to 90 degrees.

Abstract: A system for forming a vehicle component includes a first metal sheet having an aperture, a second metal sheet contacting a lower surface of the first metal sheet, an anvil supporting the first and second metal sheets beneath the aperture, and a press bit disposed above the aperture.

Abstract: A system for forming a vehicle component includes a first metal sheet having an aperture, a second metal sheet contacting a lower surface of the first metal sheet, an anvil supporting the first and second metal sheets beneath the aperture, and a press bit disposed above the aperture.

Abstract: A system for forming a vehicle component includes a first metal sheet having an aperture, a second metal sheet contacting a lower surface of the first metal sheet, an anvil supporting the first and second metal sheets beneath the aperture, and a press bit disposed above the aperture.

Abstract: A tow hook includes a monolithic additively manufactured side wall defining a vehicle attachment member, a hollow main body extending from the vehicle attachment member, and a hollow towing member extending from the hollow main body. The vehicle attachment member is configured to rigidly attached to a vehicle and the hollow towing member is configured to securely attach to a towing machine such that the vehicle is towable via the tow hook. The vehicle attachment member can be a threaded shaft with a bore extending along a length of the threaded shaft. The side includes a chamfered plurality of apertures extending from an inner surface of the side wall to an outer surface of the side wall, and having with an inner dimension along a length direction of the hollow main body greater than an inner dimension along a circumferential direction of the hollow main body.

Abstract: A visor assembly includes a visor body, an electronic device receiver and a pivot feature connecting the electronic device receiver to the visor body. The visor assembly also includes a light shield that extends between the electronic device receiver and the visor body and functions to block light passing through the gap between the visor body and the electronic device receiver when the visor body and electronic device receiver are in certain configurations.

Abstract: A sun visor assembly includes a visor body and an electronic device receiver carried on the visor body. The electronic device receiver includes a clamping feature having a slider and an opposed latching feature. The visor body may also include a USB feature and/or a viewing port extending through the visor body.

Abstract: A visor assembly includes a visor body, an electronic device receiver and a pivot feature connecting the electronic device receiver to the visor body. The visor assembly also includes a light shield that extends between the electronic device receiver and the visor body and functions to block light passing through the gap between the visor body and the electronic device receiver when the visor body and electronic device receiver are in certain configurations.

Abstract: A visor assembly includes a support, a visor body and an electronic device receiver. The visor body includes a first section having a first pivot connection with the support and a second section having a second pivot connection with the support. The electronic device receiver is carried on the second section.

Abstract: A sun visor assembly includes a visor body and an electronic device receiver carried on the visor body. The electronic device receiver includes a clamping feature having a slider and an opposed latching feature. The visor body may also include a USB feature and/or a viewing port extending through the visor body.