Hinge Design Guidelines

Hinge Qualities

The continuous hinge has excellent qualities as a versatile fastener. These include:

1. Uniform strength throughout the entire length.
   
2. Smooth pivotal action.
   
3. Easier and more accurate alignment than two or more butt hinges.
   
4. No mortising required.
   
5. Many load-bearing points (equal to the number of knuckles per leaf).
   
6. Increased rigidity.
   
7. Almost any length, width, thickness or material.
   
8. Many secondary operations are available for custom hinges: holes, offsets, PEM™ fasteners, springs and finishes.
   
9. Stock parts available in steel, stainless steel (304 and 316), aluminum (stamped and extruded) and brass.

Three Design Methods

1. Modify a stock hinge: cut down a standard length, punch holes in choice of size, spacing and shape (e.g. round, square, rectangular, obround - countersunk or plain). This is the best option for small quantities, rush delivery or experimental samples.
   
   
2. Secondary operations on a custom-run base hinge: run the base hinge in a hand blank and curl operation (usually for heavier gauges) or on a scrapless automatic line (for lighter gauges). Finish with offset or swaged leaves, rounded corners, stamped part numbers, PEM™ fasteners, springs, staked or spun pins, holes, etc. This is the most common method for moderate quantities, and generally takes longer than the first method.
   
   
3. Full custom manufacture: scrapless automatic production with custom-made tools. Eliminates the need for secondary operations. Longer lead time on first order. Quick production and lowest cost on reorders of large quantities. Note: This method may involve tooling costs.

Design Considerations

1. Select a standard product from our catalog. We have over 600 in-stock items from which to choose.
   
   
2. For most items (up to .074 thick) it is most economical to choose an even multiples of knuckle length. For heavier items that are hand blanked and curled, this is less important. We may suggest a different knuckle length, number of knuckles or overall hinge length to afford you the optimum value.
   
   
3. Partial end knuckles on lighter hinges (below .074") can bind because they are deformed in the cut off operation.
   
   
4. Unequal leaves on lighter hinges should have a total width equal to a standard width. For example, leaves of .50" and 1.50" (2.00" total - a standard) are preferable to .50" and .625" (1.125" total).
   
   
5. Use the same thickness hinge leaf as the door or base material. Exceptions are recommended when the width of the door is more than twice the height, or if a device mounted on the door doubles the moment of the door.
   
   
6. A 2:1 ratio of pin diameter to leaf thickness usually provides optimum strength. For example, a .120" diameter pin with a .060" leaf.
   
   
7. Most stock hinges are supplied with the pins not staked in place. Let us know if you require staking or not. (Those stock hinges which are staked are so noted.)
   
   
8. Standard tolerances for hinges made with secondary finishing operations are shown in the diagrams below. If you require tighter tolerances for your application, we may be able to meet your requirements with special fixtures or tooling.
   
   

   Tolerances for .025 to .062 thick material
   Tolerances for .074 and thicker material