Special Ball Lock Pins 

Carr Lane manufactures custom Ball Lock Pins for applications where standard configurations cannot meet functional requirements. Nearly any dimension or feature can be modified to suit specific tooling needs, though all modifications undergo engineering review to ensure proper function and structural integrity. 

Common Special Configurations 

Special Shank Diameters 

Ball Lock Pins can be manufactured with non-standard shank diameters to match existing hole sizes, accommodate unique clearance requirements, or integrate with customer-designed tooling systems. Shank diameter modifications require engineering review to verify that the locking balls retract completely within the shank diameter during insertion and removal. 

If the shank diameter is reduced below the standard for a given ball size, the balls may not retract fully, preventing proper insertion or causing jamming. In these cases, Carr Lane can specify smaller locking balls to maintain full retraction within the reduced shank diameter. This substitution may affect clamping force and pull-out resistance, which engineering evaluates during the review process. 

Extended Ball-to-End Distance 

Standard Ball Lock Pins position the locking balls at a fixed distance from the pin end. Applications requiring greater engagement depth, large lead in angles, or offset locking geometry may require this dimension to be increased. 

The lead angle is the chamfered or tapered entry feature at the ball end of the pin that guides the pin into the hole and allows the locking balls to retract smoothly during insertion. Standard lead angles are optimized for general-purpose insertion and alignment. Steeper lead angles improve pin insertion especially in automation.  

Flats, Grooves, and Non-Round Shank Features 

Ball Lock Pins with cylindrical shanks provide 360-degree rotational freedom, which is advantageous in many applications but undesirable in others. Flats, keyways, grooves, or other non-round features can be machined onto the shank to prevent rotation, provide clocking orientation, or create clearance for adjacent components. 

Flats are commonly added to allow additional mechanical retention. Grooves may be added for O-ring seals, retaining rings, or spring clips. Keyways allow the pin to interface with keyed bushings, fixtures, or workpieces for error-proofing. 

All non-round shank features must be evaluated for their effect on strength, particularly in high-load or cyclic loading applications. Stress concentrations at sharp corners or abrupt transitions can reduce fatigue life and may require additional material, radius transitions, or alternative geometries. 

Special Handle Configurations 

Ball Lock Pins are available in multiple handle styles, but some applications require configurations not covered by standard offerings. Common special handle requests include: 

• No Handle (Blank Shank End): Typically threaded and with an extended Spindle, No Handle BLPs are often used for automated or robotic systems where external actuation mechanisms engage the pin, or where the pin must pass through a clearance hole without interference from a handle. 
• Extended Handles: Longer grip length for manual operation in deep recesses or hard-to-reach locations. 
• Custom Grip Diameters: Larger or smaller diameters for ergonomic requirements, torque control, or clearance constraints. 
• Threaded Ends: Internal or external threads for attaching custom handles, actuation rods, or mechanical linkages. 
• Knurled or Hex Handles: For wrench or tool engagement in automated systems. Or to prevent the rotation of a pin in situ.  

Removing the handle eliminates the manual grip but retains full Ball Lock Pin functionality. Pins without handles are typically actuated using mechanical systems, threaded rods, or pneumatic actuators. 

Alternative Spring Forces 

Standard Ball Lock Pins use spring forces optimized for general-purpose manual operation. Applications requiring reduced insertion force, higher retention force, or compatibility with automated actuation may require custom spring rates. 

Lighter springs reduce the force required to compress the balls during insertion, which is advantageous for manual operation in high-cycle-rate applications or when operator fatigue is a concern. Heavier springs increase retention force and resistance to vibration-induced loosening but require higher actuation force during insertion and removal. 

Spring force modifications are typically specified for automated systems where actuation force is provided by pneumatic or hydraulic cylinders, allowing higher retention forces without manual effort penalties. 

Alternative Materials 

Standard Ball Lock Pins are manufactured in carbon steel (zinc-plated), alloy steel (4130, zinc-plated), or stainless steel (17-4PH). Applications with specific corrosion resistance, magnetic properties, temperature ranges, or material compatibility requirements may require alternative materials. 

Common material substitutions include: 

• Titanium Alloys: Low density, high strength-to-weight ratio, excellent corrosion resistance. Used in aerospace applications where weight reduction is critical. 
• Specialty Alloys: High-temperature alloys (Inconel, Hastelloy) for extreme temperature or chemically aggressive environments. These materials require specialized machining and heat treatment and are typically reserved for aerospace or chemical processing applications. 

Material substitutions may affect mechanical properties, heat treatment options, and coating compatibility. Carr Lane engineering reviews all material changes to ensure functional requirements are met. 

Engineering Review and Lead Time 

All special Ball Lock Pins undergo engineering review before quotation and manufacturing. The review process evaluates: 

• Dimensional feasibility and interference with internal components 
• Structural integrity under specified loading conditions 
• Material compatibility and heat treatment requirements 
• Manufacturing complexity and tooling requirements 

Special Ball Lock Pins typically require 6 to 12 weeks lead time depending on complexity, material availability, and heat treatment requirements. More complex specials involving custom tooling, specialty materials, or extensive testing may require longer lead times. 

Requesting Special Ball Lock Pins 

To request a special Ball Lock Pin, contact Carr Lane with the following information: 

• Application description and functional requirements 
• Dimensional specifications or marked-up drawings showing required modifications 
• Load conditions (tension, shear, cyclic loading if known) 
• Environmental conditions (temperature, corrosion exposure, magnetic sensitivity) 
• Quantity and delivery requirements 

Carr Lane engineering will review the request, provide recommendations if alternative approaches better meet the functional requirements, and issue a formal quotation with lead time. 

Contact Carr Lane at 314.647.6200 or submit a request through Web Portal.