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© 2016 www.pemnet.com 1
ThinkPad X1 Carbon (2016) Laptop Aug 16th. 2016
by XiaoMing Chen
PennEngineering®
© 2016 www.pemnet.com
ThinkPad X1 Carbon (2016) Laptop Overview
2
The Lenovo ThinkPad X1 Carbon (2016) features a carbon-fiber
reinforced chassis and magnesium body with a semi-rugged design and large 14-
inch display.
The laptop is lighter (but larger) than ultraportable competitors like the HP
EliteBook Folio 1020 and the Apple MacBook Air 13-inch.
© 2016 www.pemnet.com
ThinkPad X1 Carbon (2016) Laptop
Details & Findings
Pictures and Description of the
ThinkPad X1 Carbon (2016) Laptop
and the Disassembly Process.
3
© 2016 www.pemnet.com
ThinkPad X1 Carbon (2016) Laptop
Nine screws (circled Pink) found and engaged in the cast magnesium back
cover of the laptop. Screws are received into threaded holes in the cast magnesium
chassis. (Continued on next slide)
4
© 2016 www.pemnet.com
Back Cover Removal
(Continued from last slide) Removing the cast magnesium back cover, nine sets
of flat head screw with plain washer assemblies can be disassembled by unscrewing the
M2.5 x 5.2 parts from the washers with a Phillip 0# driver bit (circled Pink). (Continued on
next slide)
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2.5 x 5.2 9 Phillip
0#
φ4.0 5.2 0.75 Carbon
Steel
/ / / Zn-Ni NYLOK
Washer 9 / / / / Carbon
Steel
φ4.6 φ2.2 0.3 Zn-Ni /
5
© 2016 www.pemnet.com
Back Cover Removal
(Continued from last slide)
The screws cannot freely pass through the holes in washers .
The screws are engaged in the bosses protruded on the
magnesium chassis.
6
© 2016 www.pemnet.com
Plastic Snap-Fit Removal
On the back of the cast magnesium back cover six sets of plastic Snap-Fits (circled
Pink) were secured to the cover by using two Wafer head M1.2 x 2.3 screws for each. The
screws were engaged in cast magnesium back cover.
7
Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M1.2 x 2.3 6 Phillip
00#
Φ2.6 2.3 0.2 Carbon
Steel
/ / / Nickel NYLOK
© 2016 www.pemnet.com
Loudspeaker Removal Four pan head M2 x 5.6 screws (circled Pink) are removed out for getting the two
loudspeakers removal. The screws are passed through the hole in the molding plastic bases and then
screwed into the threaded holes in the bosses protruded on the magnesium body.
8
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 5.6 4 Phillip
1#
Φ3.9 5.6 1.6 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Motherboard Removal For getting the motherboard removed seven pan head M2 x 5.6 screws (circled Pink) are
unscrewed firstly. The screws are passed through the hole in the motherboard and then driven into
tapped holes in the bosses protruded on the magnesium body(continued on next slide).
9
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 5.6 7 Phillip
1#
Φ3.9 5.6 1.6 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Motherboard Removal (Continued from last slide) For getting the motherboard removed five Wafer head M2 x 3
screws (circled Pink) are untightened firstly. The products are screwed into the threaded holes in the
bosses protruded on the magnesium body (continued on next slide).
10
Size Qty. Driver Head Dia. OAL. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 3 5 Phillip
1#
Φ3.7 3.0 0.3 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Motherboard Removal (Continued from last slide) behind the double-sided adhesive strips four Wafer head M2 x
3 screws (circled Pink) are engaged into the threaded holes in the bosses protruded on the
magnesium body (continued on next slide).
11
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 3 4 Phillip
1#
Φ4.8 3 0.5 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Motherboard Removal (Continued from last slide)
continuing remove nine Wafer head M2 x 3 screws (circled Pink) around the perimeter of the unit.
The screws driven into tapped holes in the magnesium portion of the chassis.
12
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 3 9 Phillip
1#
Φ4.8 3 0.5 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Keyboard Removal In total fifty-six flat head M1.2 x 2 screws (circled Pink) are screwed through the holes
in keyboard and then driven into tapped holes in the magnesium portion of the chassis.
13
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M1.2 x 2 56 Phillip
00#
Φ2.2 2 0.3 Carbon
Steel
/ / / Bright
Nickel
NYLOK
© 2016 www.pemnet.com
Cooling Fan Removal For getting the cooling fan removal the four thick flat head M2 x 5.4 screws (circled in
Pink) are removed out firstly. The screws are passed through the holes in PCB board and then
driven into tapped holes in the magnesium portion of the chassis (continued on next slide).
14
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 5.4 4 Phillip
1#
Φ5.6 5.4 3.7 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Cooling Fan Removal
(Continued from last slide).
continuing remove four sets of Wafer head M2 x 4 screws (circled in Pink) with plastic washer
assemblies around the unit (refer to slide 5# for the assembly structure). The screws driven into
tapped holes in the magnesium portion of the chassis.
15
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 4 4 Phillip
1#
Φ5.2 4 0.8 Carbon
Steel
/ / / Nickel NYLOK
Washer 4 / / / / Plastic Φ5.2 Φ2.2 0.25 / /
© 2016 www.pemnet.com
Hinge Kits Removal Remove the four flat head M2 x 5.2 screws (circled in Pink) tightened on the left and right
hinge kits. The screws are engaged into brass heat staking inserts illustrated on the slide 23#.
16
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 5.2 4 Phillip
1#
Φ4.3 5.2 0.8 Carbon
Steel
/ / / Nickel NYLOK
© 2016 www.pemnet.com
Battery Removal With the seven pan head M2 x 5.6 screws (circled in Blue) removal the battery can be lifted off. All of
the screws are screwed into the threaded holes in the bosses protruded on the magnesium chassis.
17
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 5.6 6 Phillip
1#
Φ3.9 5.6 1.6 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Touchpad Removal
18
With the battery lifted off, eight Wafer head M2 x 3 screws (circled in Pink) found secure the
touchpad into the threaded holes in the bosses on the magnesium chassis.
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 3 8 Phillip
1#
Φ5 3 0.3 Carbon
Steel
/ / / Nickel NYLOK
© 2016 www.pemnet.com
Power ON-OFF Button Removal
19
Under the PCB board (circled in Red) the power ON-OFF button are mounted to two tapped
holes in the magnesium chassis by two M2 x 2.8mm long screws (circled in Pink).
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 2.8 2 Phillip
1#
Φ3.8 2.8 0.5 Carbon
Steel
/ / / Black
Zinc
NYLOK
© 2016 www.pemnet.com
Perimeter Bezel Removal
21
With the two Wafer head M2 x 4.2 screws removed (circled in Pink), the perimeter bezel can be
lifted off . The bezel is a molded plastic component and the screws are engaged brass inserts in
the carbon-fiber bezel cover.
Refer to slide 23# for the inserts.
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 4.2 2 Phillip
1#
Φ3.8 4.2 0.3 Carbon
Steel
/ / / Black
Nickel
NYLOK
© 2016 www.pemnet.com
Hinge Kits on Bezel Cover Removal Remove the four Wafer head M2 x 2.6 screws (circled in Pink) tightened on the left and
right hinge kits. The screws are engaged brass inserts in the carbon-fiber bezel cover. Refer to slide
23# for the inserts (continued on next slide).
22
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 2.6 4 Phillip
1#
Φ7.8 2.6 0.7 Carbon
Steel
/ / / Black
Zn-Ni
NYLOK
© 2016 www.pemnet.com
Hinge Kits Removal
(Continued from last slide).
All of the inserts are made from brass with asymmetric, piloted, opposing diagonal knurls features.
23
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2.5 6 / / 2 / Brass 3.5 2.15 / / /
M2 4 / / 2 / Brass 3.5 1.62 / / /
© 2016 www.pemnet.com
Remove the four Wafer head M2 x 2.3 screws (circled in Pink) tightened on the LED
display. The screws are engaged brass inserts in the carbon-fiber bezel cover. Refer to slide 23# for
the inserts.
24
LCD Display Removal
Size Qty. Driver Head Dia. Oal. Head
Thk.
Material O.D. I.D. Thk. Plating Coating
M2 x 2.3 4 Phillip
1#
Φ5 2.3 0.3 Carbon
Steel
/ / / Nickel NYLOK
© 2016 www.pemnet.com
Some strips of double-sided adhesive are used in the electronic components joining
(circled in Pink). The components can be pried off the carbon-fiber bezel cover, no fasteners found.
25
© 2016 www.pemnet.com 27
Fastener Summary
Section Heading slidee – Do Not Remove
ThinkPad X1 Carbon (2016) Laptop
© 2016 www.pemnet.com 28
Fastener Summary
Detail slidee – Copy and use for details. Create a table of the fasteners found in the teardown.
Note thread sizes, lengths, drivers, etc. Multiple pages
can be used for different style fasteners
• Screws (138 pieces)
•Brass Inserts (19)
–Thread Size: M1.6
–OAL: 0.0874 in (2.22 mm)
–Diameter: 0.0978 in (2.48 mm)
–Pilot Diameter: 0.0782 in (1.99 mm)
–Asymmetric, piloted, opposing diagonal
knurls.
–Brass
• Flat head
• M2.5 x 3.5 mm overall length
• 3.9 mm head diameter
• 0.8 mm head thickness
• 1# Phillips Recess
• ISO metric threads
• No locking patch used
• Bright Nickel plating
• Reference slidee # 8
Size Qty. Driver Head Dia. Oal. Head
Material Plating Coating Thk.
M1.2 x 2 56 Phillip 00# Φ2.2 2 0.3 Carbon Steel Bright Nickel NYLOK
M1.2 x 2.3 6 Phillip 00# Φ2.6 2.3 0.2 Carbon Steel Nickel NYLOK
M2 x 2.3 4 Phillip 1# Φ5 2.3 0.3 Carbon Steel Nickel NYLOK
M2 x 3 5 Phillip 1# Φ3.7 3 0.3 Carbon Steel Black Zinc NYLOK
M2 x 3 13 Phillip 1# Φ4.8 3 0.5 Carbon Steel Black Zinc NYLOK
M2 x 2.6 4 Phillip 1# Φ7.8 2.6 0.7 Carbon Steel Black Zn-Ni NYLOK
M2 x 2.8 2 Phillip 1# Φ3.8 2.8 0.5 Carbon Steel Black Zinc NYLOK
M2 x 3 8 Phillip 1# Φ5 3 0.3 Carbon Steel Nickel NYLOK
M2 x 4 4 Phillip 1# Φ5.2 4 0.8 Carbon Steel Nickel NYLOK
M2 x 4.2 2 Phillip 1# Φ3.8 4.2 0.3 Carbon Steel Black Nickel NYLOK
M2 x 5.2 4 Phillip 1# Φ4.3 5.2 0.8 Carbon Steel Nickel NYLOK
M2 x 5.4 4 Phillip 1# Φ5.6 5.4 3.7 Carbon Steel Black Zinc NYLOK
M2 x 5.6 17 Phillip 1# Φ3.9 5.6 1.6 Carbon Steel Black Zinc NYLOK
M2.5 x 5.2 9 Phillip 0# φ4.0 5.2 0.75 Carbon Steel Zn-Ni NYLOK
© 2016 www.pemnet.com 29
Fastener Summary
Detail slidee – Copy and use for details. Create a table of the fasteners found in the teardown.
Note thread sizes, lengths, drivers, etc. Multiple pages
can be used for different style fasteners
• Brass Inserts (10 pieces)
– Thread Size: M2/M2.5
– OAL: 2.0 mm
– Diameter: 3.5mm
– Asymmetric, tapered, opposing diagonal knurls.
– Brass
• Carbon Steel Washers (9 pieces)
– O.D.: 4.6mm
– I.D.: 2.2 mm
– Thickness: 0.3mm
– Plating: Zn-Ni
• Plastic Washers (4 pieces)
– O.D.: 5.2mm
– I.D.: 2.2 mm
– Thickness: 0.25mm
– Plating: None
© 2016 www.pemnet.com
Alternate Solutions
PennEngineering® recommendations of alternate hardware and cost savings
opportunities.
Section Heading slidee – Do Not Remove
30
© 2016 www.pemnet.com 31
microPEM Micro Screws
PennEngineering has license with
Torx®, Torx Plus®, and Phillips®
Drive System and has capability to
do Zinc, Nickel and Zn-Ni plating
with different color.
PEM can provide existing
micro screws for the applications, no
change to the design.
© 2016 www.pemnet.com 32
microPEM Micro TackSerts®
The TackSert® fastener is released for use in
metal, die-cast or plastics.
This is a one-time, permanent use, fastener.
The keyboard sub-assembly may not need to
be removed.
Currently tapping magnesium chassis and
threading micro screws into the tapped holes.
TackSerts eliminate the tapping step and
replace the screws. To be installed with axial
pressure for a lower total installed cost.
© 2016 www.pemnet.com 33
microPEM Micro SI
PennEngineering can provide existing
micro brass inserts for the applications,
no change to the design.
PennEngineering offers MSIB fasteners.
Symmetric, piloted design for ease of
installation and handling.
Can be installed by heat-stake, ultra-sonics
or cold-press.
Symmetric, piloted design for ease of
installation and handling.
Aluminum option for weight reduction.
© 2016 www.pemnet.com 34
microPEM Micro SCB/SCBJ
Micro versions of SCB and SCBJ can be
used as a replacement for screw-washer
assemblies that hardware be
constrained.
The SCB and SCBJ offer an economical
solution for retained screws.
The SCB and SCBJ will provide axial
float, meaning it can move up and down
once disengaged from the mating
hardware without forcing the joint apart.
The SCB and SCBJ can be used to jack,
or force apart, the assembled joint by
turning out the screw.
© 2016 www.pemnet.com 35
Conclusions and Summary
ThinkPad X1 Carbon (2016) Laptop
Section Heading slidee – Do Not Remove
© 2016 www.pemnet.com 36
Conclusion
Detail slidee – Copy and use for details. Summarize the findings and alternate
solutions.
There are 14 different types of screws, using 3 different driver
sizes. Also there are 138 tapped holes and 10 brass inserts in this laptop.
PennEngineering can provide the screws and inserts currently used with no
change to the design.
When and where possible, using one common driver size or type
can reduce assembly times and costs. Consolidation of screw sizes and
lengths will also benefit the manufacturer.
There are cost savings opportunities by changing many of the
threaded joints to TackSerts. 56 pierces of M1.2 x 2 screws can be replaced
with microPEM Micro TackSerts® .
Replacing the 56 pierces M1.2 threads in the magnesium chassis
with unthreaded holes would result in substantial cost saving opportunities.
In total 13 sets of screw-washer assemblies be used for screws can move
up and down once disengaged from the mating hardware without forcing the
joint apart. As a possible solution, Micro versions of SCB and SCBJ can be
used as a replacement for screw-washer assemblies that hardware be
constrained.