Materials

Learn about all the different materials you will encounter in FRC.

Aluminum

Aluminum is one of the most important materials in FRC. Different aluminum series have very different strengths, machining behavior, and real-world use in robot components.

6061-T6 Aluminum

6061-T6 is the most common structural extrusion material in FRC.

Properties:

Typical use:

5052 Aluminum

5052 is most commonly used as sheet metal stock in FRC.

Properties:

Typical use:

7000 Series Aluminum (e.g., 7075)

7000 series aluminum is a high-strength aerospace-grade material that is significantly stronger than 6061.

Properties:

Typical use:

7000 Series in COTS FRC Components (WCP and Similar Vendors)

In FRC, 7000 series aluminum (commonly 7075) is often used in COTS (Commercial Off-The-Shelf) components, especially from vendors like West Coast Products.

Instead of teams machining it themselves, it is typically found in:

Why vendors use it:

6061 vs 5052 vs 7000 Series

Key Idea

Most FRC robots are built from 6061 extrusion and 5052 sheet, but 7000 series aluminum appears frequently in COTS components from vendors like West Coast Products because it enables stronger, lighter, and more compact high-performance parts.

Steel

Steel is a strong, heavy metal sometimes used in FRC for high-strength or wear-resistant applications. While aluminum is more common, steel is chosen when extra strength or durability is required.

Why FRC Teams Use Steel

Steel is used because it:

Common Types of Steel in FRC

Mild Steel

Hardened Steel

Common Applications

Limitations

Key Idea

Steel is used in FRC when strength and durability matter more than weight. It is most commonly found in shafts, fasteners, and high-load components rather than full structural frames.

Polycarbonate

Polycarbonate (often called “polycarb”) is a tough, transparent plastic widely used in FRC for protective and structural sheet applications.

Why FRC Teams Use Polycarbonate

Polycarbonate is used because it:

Common Applications

Properties to Know

Important Handling Notes

Key Idea

Polycarbonate is a strong, impact-resistant plastic that is ideal for protective and lightweight structures in FRC. Proper drilling and fastening techniques are important to prevent cracking and extend part life.

SRPP (Glass-Filled Polypropylene)

SRPP is a glass-filled polypropylene sheet material commonly used in FRC, often supplied or popularized through vendors like West Coast Products.

What It Is

SRPP is a reinforced plastic made from:

This combination makes it significantly stronger and stiffer than standard plastic sheet.

Why FRC Teams Use SRPP

SRPP is used because it:

Common Applications

Manufacturing Notes

Limitations

Key Idea

SRPP is a lightweight, glass-filled plastic sheet material used in FRC as a strong alternative to aluminum plates in lower-to-medium load applications, especially where weight savings matter.

Plywood

Plywood is a layered wood composite made by pressing thin sheets of wood veneer together with alternating grain directions. This structure gives it strength and resistance to cracking compared to solid wood.

Why FRC Teams Use It

Plywood is used because it:

Common Use in FRC

Plywood is primarily used as bumper backing, where it:

Material Notes

Limitations

Key Idea

Plywood is a strong, low-cost composite material used in FRC for structural support in bumper systems, where rigidity and durability are more important than weight savings.

Common 3D Printer Filaments

3D printing filaments in FRC form a spectrum of materials that trade off between ease of printing, stiffness, toughness, and flexibility. Understanding how they relate helps teams choose the right material for each application instead of defaulting to one.

The “Spectrum” of Filaments

You can think of common filaments as a progression:

As you move right:

Rigid vs. Tough vs. Flexible

PLA (Rigid, easy, brittle)

PETG (Tough, slightly flexible)

ABS (Tough + heat resistant)

Nylon (Very tough, wear-resistant, flexible)

TPU (Flexible, elastic)

How They Compare in Use

Key Relationship Idea

These filaments are not separate choices—they form a progression from rigid and easy (PLA) to tough (Nylon) to flexible (TPU). Most FRC teams use a mix depending on whether the part needs accuracy, strength, wear resistance, or compliance.

When to use which material

Each material used in FRC has distinct mechanical and manufacturing properties that determine how it behaves under load, during machining, and in real-world robot use.

6061-T6 Aluminum

5052 Aluminum

Polycarbonate

SRPP (Glass-Filled Polypropylene)

Steel

Plywood

Key Idea

Each material behaves differently under stress, machining, and impact. Understanding these unique properties allows FRC teams to choose the right material for strength, weight, flexibility, and durability requirements.

Sheet Thickness

Sheet materials in FRC come in standard thickness increments. These increments strongly affect stiffness, weight, and how parts behave under load.

Common Sheet Thickness Increments

Most sheet materials (aluminum, polycarbonate, plastics) are typically available in:

These standard sizes are what most FRC designs are based on.

How Thickness Affects Strength

1/16"

1/8"

3/16"

1/4"

3/8"

1/2"

Why Teams Pocket Parts

Key Idea

FRC sheet design is about balancing standard thickness options with strategic material removal. Pocketing helps teams keep strength where needed while eliminating excess weight.