Project Title: XPress Condulet™ Threadless Assembly System
Project Summary: The XPress Condulet™ Threadless Assembly System was developed in collaboration with sponsor Eaton Corporation to address inefficiencies in traditional electrical conduit installations.
Standard methods require manual threading of the steel conduit, which is labor-intensive, time-consuming, and costly in largescale applications. The team engineered an innovative, threadless
connection system that utilizes a segmented external threading profile and compression fit to secure conduit without damaging it. Their final design consists of a two-part assembly—a conduit body and a tightening nut—with internal teeth that deform into the conduit wall under uniform radial pressure from the nut tightened on external threads. Additional design elements, such as a built-in O-ring and staggered rows of teeth, enhance environmental sealing and long-term reliability. The system meets UL and NEMA standards for mechanical strength, water resistance, and dust protection. It is scalable across various conduit sizes and compatible with Eaton’s existing sand casting and CNC manufacturing processes. Finite element analysis and physical testing validated the performance and material integrity of the design, which uses recycled Eaton Feraloy for added sustainability. The success of this project led to the positioning of a provisional patent, with the Syracuse University team recognized as named inventors.
