Riveting

• Why FRC Teams Use Rivets
• Blind Rivets
• Sizes and Grip Range
• Rivet Guns
• Common Mistakes

Why FRC Teams Use Rivets

Rivets are permanent mechanical fasteners commonly used in FRC for joining thin materials such as sheet metal and gussets to structural members.

What Is a Rivet?

A rivet is a fastener that permanently joins two or more materials by expanding inside a drilled hole. Once installed, it cannot be removed without drilling it out.

Why FRC Teams Use Rivets

FRC teams use rivets because they are:

• Fast to install
• Lightweight compared to bolts and nuts
• Reliable under vibration
• Ideal for thin materials like aluminum sheet and gussets
• Useful in high-density assemblies where space is limited

Common Applications

Rivets are often used for:

• Attaching gussets to aluminum extrusion
• Mounting sheet metal panels
• Securing lightweight structural brackets
• Enclosures and protective panels

Installation Tool

Rivets are installed using a hand rivet gun or pneumatic rivet tool, which pulls the mandrel and expands the rivet body inside the hole.

Limitations

• Permanent (must be drilled out to remove)
• Not suitable for joints that require frequent adjustment
• Limited strength compared to bolted joints in high-load areas

Best Practice

• Use correct rivet size for the drilled hole
• Ensure materials are tightly clamped before riveting
• Deburr holes before installation
• Avoid using rivets in joints that may need future disassembly

Key Idea

Rivets are a fast, lightweight, and vibration-resistant fastening method, making them ideal for sheet metal and non-adjustable structural joints in FRC robots.

Blind Rivets

Blind rivets (also called “pop rivets”) are a common fastening method in FRC used to join materials when you only have access to one side of the joint.

What Is a Blind Rivet?

A blind rivet is a fastener that is installed from one side of the material using a rivet gun. When set, it expands and locks the materials together permanently.

Why They Are Called “Blind”

They are called blind rivets because you do not need access to the back side of the joint during installation.

This is useful when:

• One side of the assembly is enclosed
• You cannot reach the back of the material
• Working inside tight robot structures

Why FRC Teams Use Them

Blind rivets are popular in FRC because they are:

• Fast to install
• Lightweight
• Strong enough for sheet metal and gussets
• Ideal for tight or inaccessible areas

Common Uses

• Mounting sheet metal panels
• Attaching gussets to extrusion
• Securing enclosures or covers
• Light structural connections

Installation Tool

Blind rivets are installed using a:

• Hand rivet gun
• Pneumatic rivet tool (for faster assembly during build season)

The tool pulls a mandrel through the rivet, expanding it and locking it in place.

Limitations

• Permanent (must be drilled out to remove)
• Not suitable for high-load structural joints
• Requires correct hole sizing for a tight fit

Best Practice

• Match rivet size to drilled hole
• Clamp materials before riveting
• Deburr holes for better seating
• Ensure the rivet is fully set before releasing the tool

Key Idea

Blind rivets are used when access is limited but a fast, lightweight, and secure fastening method is needed in FRC fabrication.

Sizes and Grip Range

Blind rivets are a common fastening method in FRC used to join sheet metal, gussets, and extrusion when access is only available from one side. Two important factors when selecting rivets are size and grip range.

3/16" Rivets (Common FRC Size)

3/16" rivets are larger diameter blind rivets used when a stronger joint is needed.

Best uses:

• Structural gusset connections
• High-load or high-vibration joints
• Areas where extra strength is more important than weight

Requirements:

• Correctly sized drilled hole (3/16")
• Proper grip range selection for material thickness

Tradeoffs:

• Heavier than smaller rivets
• Requires more force to install
• Takes up more material space

Grip Range

Grip range is the total thickness of material a rivet can properly clamp.

If grip range is incorrect:

• Too short → rivet may not set correctly or could pull out
• Too long → joint will be loose and weak

Correct grip range ensures:

• Proper rivet expansion
• Strong, tight joints
• Reliable long-term fastening

Best Practice

• Measure total material thickness before selecting rivets
• Always match grip range to your material stack
• Deburr holes before installation
• Ensure rivet is fully seated before releasing the tool

Key Idea

In FRC, 3/16" rivets are used for stronger structural joints, but only work correctly when paired with the proper grip range for the material thickness.

Rivet Guns

A rivet gun is a tool used to install blind rivets in FRC. It works by pulling a mandrel through the rivet body, expanding it and locking materials together permanently.

Types of Rivet Guns

Hand Rivet Gun

• Manually operated with handles
• Most common in FRC teams
• Good for small to medium build volume

Pneumatic Rivet Gun

• Powered by compressed air
• Much faster and requires less effort
• Used in high-volume assembly during build season

How a Rivet Gun Works

1. Insert rivet into the drilled hole
2. Place rivet gun nose onto the mandrel
3. Squeeze or activate the tool
4. The mandrel is pulled, expanding the rivet
5. The mandrel snaps off once fully set

Proper Use

• Ensure correct rivet size and grip range before installing
• Keep the gun aligned straight with the rivet
• Apply steady force until the mandrel breaks cleanly
• Make sure the rivet head sits flush against the material

Common Mistakes

• Pulling at an angle (can weaken the joint)
• Not fully setting the rivet
• Using the wrong nose piece for the rivet size
• Reusing partially set rivets

Maintenance

• Empty broken mandrels from the tool regularly
• Keep jaws clean for proper gripping
• Check nose pieces for wear or damage

Key Idea

Rivet guns turn a simple blind rivet into a strong, permanent joint. Proper alignment, correct sizing, and full actuation are essential for reliable FRC construction.

Common Mistakes

Rivets are simple to install, but small errors can lead to weak joints, misalignment, or failed assemblies in FRC robots.

Incorrect Hole Size

• Using a hole that is too large reduces holding strength
• Using a hole that is too small can deform the rivet or prevent installation

Always match the drilled hole size to the rivet specification.

Wrong Grip Range

• Too short → rivet may not fully set or can pull out
• Too long → joint will be loose and weak

Grip range must match the total material thickness.

Poor Alignment

• Rivets installed at an angle weaken the joint
• Misaligned holes can cause stress on the connection
• Parts may not sit flush against each other

Not Deburring Holes

• Sharp edges can prevent proper seating
• Burrs may interfere with rivet expansion
• Can lead to uneven or weak joints

Incomplete Setting

• Rivet not fully pulled can loosen over time
• Mandrel should snap cleanly when properly installed

Overusing Rivets

• Using too many rivets can add unnecessary weight
• Can weaken material if holes are too close together

Key Idea

Strong riveted joints depend on correct hole size, proper grip range, clean installation, and good alignment. Most rivet failures come from small setup mistakes rather than the rivet itself.