This work deals with the structural analysis of screw clamps for external fixator devices. Screw clamps are widely used in external fixators as a means to connect the half-pins to the fixator body. The analysis is carried out by both numerical and experimental techniques, based on the case study of a clamp produced by Citieffe (Bologna, Italy). As a preliminary activity, the tribological parameters involved in the screw–clamp interaction have been characterized by means of a mixed finite element analysis and experimental procedure. Then, an assessment of the current design of the clamp has been carried out. A re-design has been proposed, which, based on some targeted geometrical modifications, allows achieving higher strength requirements with the same overall dimensions and type of materials. A higher load-bearing capability for a given size may allow the fixator to be used on a broader population. Finally, a list of good practices for the design of this kind of clamps has been proposed.
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