Fabrication

As a mechanical engineer on the team you will be working in the shop constantly. The shop is a dangerous place for your eyes so in order to preserve your vision use safety glasses.

Particularly safety glasses with the code:

ANSI Z87

There are two types of safety glasses

Over-Prescription Safety Glasses - This is for people who already have prescription glasses who want to wear safety glasses over them.

Safety Glasses - This is for people without prescription glasses.

Make sure you do NOT bring black safety glasses to competition as FRC volunteers must be able to clearly see your eyes.

Safety

Clothing and Hair

Appropriate clothing and hair management are essential for maintaining a safe working environment. Loose clothing, jewelry, and unsecured hair can become caught in moving machinery, power tools, and rotating equipment, creating serious hazards.

Clothing Requirements

Students working in the shop must wear clothing that allows them to work safely around tools and machinery.

Closed-toe shoes must be worn at all times. Sandals, flip-flops, and open-toed shoes are prohibited.
Clothing should fit appropriately and should not have excessively loose sleeves, strings, or fabric.
Hood strings, lanyards, and drawstrings should be removed, tucked in, or secured before operating equipment.
Long pants are recommended when working with machinery, metal stock, or sharp materials
Rings, bracelets, necklaces, and dangling earrings should be removed before working in the shop.

When working in the shop, don't use gloves unless you are lifting a sharp or heavy object. This is because gloves can get caught on rotating tools.

Hair Requirements

Long hair can easily become caught in rotating tools and machinery.

Hair extending below the shoulders must be tied back or otherwise secured while working in the shop.
Ponytails, braids, buns, or hair ties may be used to keep hair away from moving equipment.
Hats or hair coverings may be worn if they do not interfere with safety glasses or other protective equipment.

Why These Rules Matter

Rotating machinery such as drills, saws, motors, and other equipment can quickly pull loose clothing or hair into moving parts. These incidents can occur in fractions of a second and may result in serious injuries.

Safety

Emergency Procedures

The safety of all team members is the highest priority. In the event of an emergency, students should remain calm, notify a mentor or team leader immediately, and follow established safety procedures. No student should attempt to handle a serious emergency alone.

Reporting an Emergency

If an injury, fire, or other emergency occurs:

Stop all work immediately.
Turn off and unplug any operating machinery if it is safe to do so.
Alert nearby students and mentors.
Contact a mentor, teacher, or designated safety captain.
Follow instructions from supervising adults and emergency personnel.

Medical Emergencies

For serious injuries:

Do not move the injured person unless they are in immediate danger.
Notify a mentor or teacher immediately.
Call emergency services if necessary.
Keep the area clear to provide space for responders.
Remain with the injured person until help arrives.

For minor injuries:

Report the injury to a mentor or safety captain.
Use the first aid kit as directed by an adult.
Even small cuts or burns should be cleaned and treated promptly.

Fire Emergencies

If a fire occurs:

Alert everyone in the shop immediately.
Activate the building fire alarm if necessary.
Evacuate the area using designated exits.
Do not attempt to fight a fire unless you have been trained and it is safe to do so.
Move to the designated meeting location outside the building.
Do not re-enter the building until authorized by emergency personnel.

Battery Emergencies

Robot batteries contain significant stored energy and can become dangerous if damaged.

If a battery is smoking, leaking, or overheating, notify a mentor immediately.
Keep people away from the battery.
Use appropriate battery handling procedures and approved fire suppression methods if trained to do so.
Do not touch damaged batteries without proper protection.

Chemical Spills

If lubricants, adhesives, cleaning products, or other chemicals spill:

Notify a mentor immediately.
Keep students away from the affected area.
Follow the instructions for the specific material if available.
Clean the spill only if authorized and properly equipped.

Evacuation Procedures

When instructed to evacuate:

Stop work immediately.
Turn off equipment if it is safe to do so.
Leave tools and materials behind.
Walk calmly to the nearest exit.
Proceed to the designated meeting location.
Remain with the team until attendance has been taken.

Emergency Equipment Locations

All team members should know the locations of:

First aid kits
Fire extinguishers
Emergency exits
Eye wash stations (if available)
Emergency contact information

After an Incident

Any injury, near miss, equipment failure, or unsafe condition should be reported to a mentor or safety captain. Reporting incidents helps the team improve safety procedures and prevent future accidents.

Calipers

A precise device used for measuring distances from 0-6 inches.

Calipers

How to read the measurment

Digital Calipers

1.Close the jaws of the calipers shut.

2.Click the "Zero" Button on the calipers.

3.Open the jaws and clamp on the part you wish to measure.

4.Tighten the set screw.

5.Read it!

Dial Calipers

1.Close the jaws of the calipers shut.

2.Unscrew the dial mechanism

3.Rotate the dial until the "0" is matched with the needle

4.Open the jaws and clamp on the part you wish to measure.

5.Tighten the set screw.

6.Read it!

Informational video on reading dial calipers: Click Here!

Calipers

Different types of measurement

There are 3 different ways to measure with calipers.

1.Measuring the external dimension of a part. To do this clamp on the outside using the external measuring jaws.

EX: Measuring the side lengths of a cube.

2.Measuring the internal dimension of a part. To do this clamp on the inside using the internal measuring jaws.

EX: Measuring the slot width or diameter of a circle in a part to confirm tolerances.

3.Measuring the depth of a part. To do this use the depth gauge at the end of the calipers.

EX: Measuring to the bottom of a threaded hole to pick out the right sized bolt.

Fasteners

Learn about what holds robots and the field together

Fasteners

Introduction to Fasteners

Fasteners are components used to mechanically join two or more parts together. In FRC, fasteners are essential for building rigid structures, attaching mechanisms, and allowing robots to be serviced and repaired efficiently.

Common types of fasteners include bolts, screws, rivets, nuts, and specialty locking hardware. Choosing the correct fastener affects strength, reliability, and how easily a robot can be maintained.

Fasteners

Bolt and Nut vs. Tapped Hole

Bolt and Nut

A bolt passes through two or more materials and is secured with a nut on the opposite side.

Advantages:

High strength connections
Easy to replace damaged hardware
Good for structural joints

Disadvantages:

Requires access to both sides
Can be slower to assemble

Tapped Hole

A tapped hole has internal threads cut into the material, allowing a screw to thread directly into the part.

Advantages:

Only one-side access needed
Clean and compact assemblies

Disadvantages:

Threads can strip if over-tightened
Not ideal for thin materials

Fasteners

Phillips Screws

Phillips screws are cross-head fasteners designed to allow controlled slipping (cam-out) under high torque.

Common driver sizes:

PH0: Very small electronics
PH1: Small screws and sensors
PH2: Most common hardware
PH3: Large fasteners

Correct Driver Fit

A proper driver:

Fully fills the screw head
Has minimal wobble
Engages all four contact points

Signs of Incorrect Fit

Stripping or rounding of the head
Slipping during tightening
Excessive force required

Using the correct driver size is one of the simplest ways to prevent hardware failure.

Fasteners

Washers

Washers are thin discs placed under fastener heads or nuts.

Flat Washers

Distribute load over a larger area
Prevent surface damage

Lock Washers

Help resist loosening from vibration
Less common in modern FRC than Nylock nuts

Fender Washers

Extra-large diameter
Used on thin materials like sheet metal or polycarbonate

Fasteners

Nylock Nuts

Nylock nuts contain a nylon insert that increases friction on the threads.

Advantages:

Resist loosening due to vibration
Reliable for moving mechanisms
Common in robotics assemblies

Limitations:

Nylon degrades under high heat
Reuse is limited (loses effectiveness over time)

Fasteners

Rivets

Rivets are permanent mechanical fasteners used to join materials, especially aluminum.

Common sizes:

1/8 inch
3/16 inch

Advantages

Lightweight
Fast installation
Strong in shear applications

Limitations

Not removable without drilling out
Requires correct grip range selection

Rivets are commonly used in chassis and sheet metal assemblies.

Fasteners

Threadlocker

When to Use

Use blue threadlocker when:

Fasteners are exposed to vibration
A joint must stay secure over time
A Nylock nut is not practical

Polycarbonate Warning

Do not use threadlocker in contact with polycarbonate (Lexan) or other stress-sensitive plastics.

It can cause cracking or “crazing” in the material
It can weaken plastic parts over time

Instead, use:

Nylock nuts
Proper mechanical fastening methods (washers, spacers, correct bolt length)

Application

Apply a small amount to metal threads only
Avoid excess that could spread onto plastic
Let the joint fully tighten before curing

Key Idea

Threadlocker is a backup for vibration resistance, not a replacement for proper fastener selection or good mechanical design.

Measuring and Marking

Learn how to properly mark materials to be cut.

Measuring and Marking

Introduction to FRC Extrusion

Rectangular aluminum extrusion is used in FRC to build robot frames and structural mechanisms. The strength, stiffness, and weight depend on both size and wall thickness.

Common Extrusion Sizes

1" × 1"

Small, lightweight structural member
Used for mechanisms and compact structures

2" × 1"

Most common FRC structural extrusion
High stiffness in the 2" direction
Used for drivetrains and main frames

2" × 2"

Heavy-duty, very rigid
Used for high-load structures
Heavier, used only when needed

Wall Thickness (WCP Options)

West Coast Products (WCP) commonly offers:

0.063" — Lightweight, lower strength
0.090" — Balanced strength and weight (most common)
0.125" — Maximum strength and stiffness

Thicker walls increase strength but also add weight.

0.5 Inch Hole Spacing

Many FRC designs use a 0.5 inch grid pattern when drilling extrusion.

This means holes are placed every half inch (0.5", 1.0", 1.5", etc.) to create consistent mounting locations.

This system:

Matches CAD layouts
Improves alignment between parts
Makes fabrication repeatable and accurate
Helps standardize robot construction

Key Idea

Different extrusion sizes and wall thicknesses control strength and weight, while the 0.5 inch grid system ensures accurate and repeatable assembly.

Measuring and Marking

How to Measure Accurately with a Tape Measure

Accurate measurement is critical in FRC fabrication. Small errors can cause misaligned parts and poor assembly fit.

Reference Edge (Most Important Rule)

Always measure from a consistent, known reference point. For FRC extrusion, this should be the factory-cut end of the tube.

This ensures every measurement starts from a true, flat surface.

Using the Tape Measure

Seat the hook firmly on the factory edge
Keep the tape straight and tight
Read at eye level to avoid parallax error
Use the smallest increment you can reliably read

Offset Measurement Method (High-Precision Technique)

For improved accuracy in tight tolerance work, you can use an offset method:

Align the 1 inch mark of the tape with the factory edge
Read the measurement from that point
Subtract 1 inch from the final value

This reduces small errors caused by hook movement or wear.

Using a Speed Square for Marking

A speed square is used to create accurate 90° layout lines.

How to use it:

Place the square’s fence against the factory edge
Mark your measured point
Draw a straight line across the extrusion using the square edge

This ensures:

Square cuts
Accurate drill lines
Proper part alignment

Common Mistakes

Measuring from a damaged or non-factory edge
Forgetting to subtract the 1 inch offset
Letting the tape twist or sag
Drawing marks without a square

Key Idea

Accuracy comes from using a consistent reference edge and controlling measurement error through either direct reading or a properly applied offset method.

Measuring and Marking

Hole Layout Using a Single Datum (Plates + Center Punching)

Accurate hole placement in FRC depends on using a consistent datum and properly marking drill locations before cutting.

Using a Datum for Hole Layout

A datum is a fixed reference edge used to measure all features from.

For plates, the best datum is usually:

A straight factory edge of the material

All hole locations should be measured from this same edge:

Measure X distance from the datum
Measure Y distance from the datum
Do not switch reference edges between holes

Using one datum ensures:

Holes stay aligned in a grid
Parts match CAD layouts
Errors do not accumulate across measurements

Marking Hole Locations

Once measurements are made:

Mark each hole location clearly with a pencil or scribe
Use a combination square or speed square to ensure straight layout lines when needed
Double-check critical dimensions before punching or drilling

Center Punching

A center punch is used to lock in the exact drill location before drilling.

Why it is used:

Prevents the drill bit from “walking” (sliding off the mark)
Improves accuracy on metal surfaces
Creates a small indentation that guides the drill bit

How to use it:

Place the punch directly on the marked point
Hold it steady and perpendicular to the surface
Strike firmly with a hammer to create a visible dent

Best Practice Workflow

Choose a single datum edge
Measure all hole positions from that datum
Mark each point clearly
Use a center punch on every hole location
Drill carefully, keeping the bit centered in the punch mark

Key Idea

Good hole accuracy comes from consistent measurement from the same datum and center punching every mark before drilling.

Measuring and Marking

Scribing and Marking Tools

Accurate layout work in FRC depends on clearly marking where cuts and holes will be made. Scribing and marking tools help create precise, repeatable reference lines before drilling or cutting.

Pencil and Marker

Used for general layout on metal and plates
Easy to see and quick to apply
Best for rough or medium-precision marking

Limitations:

Can be thick or imprecise
Marks can wear off during handling

Scribe

A scribe is a sharp tool used to scratch fine lines into metal surfaces.

Advantages:

Very high precision
Permanent marking (does not wipe off easily)
Thin, accurate lines for hole centers and cut lines

Best use:

High-accuracy hole layout
Critical alignment features
Final marking before center punching

Combination Square

A combination square is used to mark straight, perpendicular lines.

Uses:

Drawing 90° lines from a datum edge
Checking squareness of parts
Extending measurement marks across a plate or extrusion

Speed Square

A speed square is used for quick and accurate right-angle marking.

Uses:

Fast layout on extrusion and plate
Marking cut lines
Checking alignment during fabrication

Best Practice

Always measure from a single datum first
Mark lightly before final scribing
Use a square tool to ensure all lines are perpendicular
Double-check critical marks before punching or drilling

Key Idea

Good fabrication starts with good marking. Scribes and squares turn measurements into accurate, repeatable reference lines that prevent errors during drilling and cutting.

Measuring and Marking

Tolerance and Why ±1/32" Matters

"Measure twice, cut once"

What Is Tolerance?

Tolerance defines how far a part can deviate from its intended dimension while still working correctly.

Example:

10.000" ± 1/32"
This means the part can be slightly larger or smaller and still be acceptable

Why ±1/32" Matters in FRC

A tolerance of 1/32 inch (0.031") may seem small, but in robotics it can:

Prevent holes from lining up correctly
Cause shafts or bearings to bind
Create misalignment in drivetrains or elevators
Stack into larger errors across assemblies

Small errors add up when multiple parts depend on each other.

When Tight Tolerances Are Needed

Tight tolerances (like ±1/32") are important when:

Aligning bearing holes
Mounting shafts or gears
Building drivetrain frames
Connecting pre-cut or CAD-matched parts

When Loose Tolerances Are Acceptable

Looser tolerances are acceptable when:

Mounting non-critical brackets
Creating sensor mounts with adjustment
Working with slots or oversized holes
Designing parts that need adjustability

Best Practice

Measure twice before cutting or drilling
Use the same datum for all features
Center punch hole locations before drilling
Drill pilot holes before final sizing when precision is critical

Key Idea

Tolerance is not just a number—it is what determines whether parts fit together correctly or create assembly problems. In FRC, ±1/32" can be the difference between a smooth assembly and a misaligned mechanism.

Hand Tools

How to use all of the different hand tools in the shop.

Hand Tools

T-Handles and Wrenches

T-handles and wrenches are common hand tools used in FRC for installing and removing fasteners. Choosing the right tool improves speed, safety, and prevents damage to hardware.

T-Handles

T-handles are used with hex (Allen) fasteners and provide better torque control than standard L-shaped hex keys.

Advantages:

Higher torque capability
Faster repeated fastening
Better grip and control
Reduced hand fatigue during long assembly sessions

Best use in FRC:

Drivetrain assembly
Mechanisms with many hex fasteners
Repetitive tightening tasks

Wrenches

Wrenches are used on external hex fasteners such as nuts and bolt heads.

Common types in FRC:

Combination wrenches (open + box end)
Ratcheting wrenches (faster operation in tight spaces)

Advantages:

Strong torque application
Works with nuts and bolt heads
Useful in tight or awkward spaces

Proper Use

Ensure full contact with the fastener before applying force
Keep tools aligned to avoid rounding edges
Use steady pressure instead of sudden force
Match tool size exactly to fastener size

Common Mistakes

Using incorrect wrench size (causes stripping/rounding)
Applying force at an angle
Using pliers instead of proper wrenches
Not fully seating the tool before turning

Key Idea

T-handles are best for fast, controlled tightening of hex fasteners, while wrenches are essential for nuts and bolts. Using the correct tool protects hardware and improves build quality.

Hand Tools

Ratchets and Sockets

Ratchets and sockets are common hand tools in FRC used for quickly tightening or loosening nuts and bolt heads. They are especially useful in tight spaces where a wrench cannot fully rotate.

Ratchet

A ratchet is a handle tool that allows continuous tightening or loosening without removing the tool from the fastener.

Advantages:

Fast operation
Works well in confined spaces
Direction can be switched easily (tighten/loosen)
Reduces time during assembly and repairs

Sockets

Sockets attach to the ratchet and fit over the fastener.

Types used in FRC:

Standard sockets (for nuts and bolt heads)
Deep sockets (for longer bolts or protruding threads)

Key rule:

Always match socket size exactly to the fastener to avoid rounding

Proper Use

Fully seat the socket on the nut or bolt head
Keep the ratchet aligned straight with the fastener
Apply steady force instead of jerking motions
Switch direction carefully to avoid over-tightening

Common Mistakes

Using the wrong socket size
Not fully seating the socket before turning
Using excessive force at an angle (causes rounding)
Forgetting to switch ratchet direction

Key Idea

Ratchets and sockets make fastener work faster and more efficient, but only when the correct size is used and the tool is properly aligned with the hardware.

Hand Tools

Pliers and Vice Grips

Pliers and vice grips are gripping tools used in FRC for holding, bending, and temporarily securing parts. They are not primary fastening tools, but they are useful for support tasks during assembly.

Pliers

Pliers are hand tools used to grip, bend, or hold small parts.

Common uses in FRC:

Holding nuts in tight spaces
Bending wire or light metal
Removing or adjusting small components

Types:

Needle-nose pliers (precision work in tight areas)
Standard pliers (general gripping and bending)

Vice Grips (Locking Pliers)

Vice grips are adjustable pliers that lock into place with high gripping force.

Advantages:

Strong, adjustable grip
Can hold parts without continuous hand pressure
Useful for temporary clamping

Common uses in FRC:

Holding bolts or nuts in place
Temporary clamping of parts during assembly
Removing stripped or stuck fasteners

Proper Use

Adjust grip before locking vice grips into place
Avoid over-tightening, which can damage parts
Use only when a proper tool (wrench or socket) is not practical
Release locking mechanism carefully to avoid sudden movement

Common Mistakes

Using vice grips as a permanent fastening solution
Over-tightening and damaging hardware
Slipping off due to poor adjustment
Using pliers instead of the correct size wrench or socket

Key Idea

Pliers and vice grips are support tools in FRC. They are best used for holding and adjusting parts, not for replacing proper fastener tools like wrenches or sockets.

Hand Tools

Deburring Tools

Deburring tools are used in FRC fabrication to remove sharp edges (burrs) created after cutting, drilling, or machining metal parts. Proper deburring improves safety, fit, and part durability.

What Is a Burr?

A burr is a sharp or rough edge left behind after:

Drilling holes
Cutting aluminum extrusion or plate
Machining or grinding

Burrs can cause:

Cuts and injuries
Poor part fitment
Difficulty inserting bolts or rivets

Deburring Tools

Hand Deburrer

Small rotary tool with a cutting blade
Used to chamfer hole edges
Fast and easy for repeated use

Deburring Bit (in drill)

Installed directly into a drill
Quickly cleans hole edges
Common in high-volume fabrication

File or Sanding Tool

Used for larger edges or cut surfaces
Removes sharp corners and smooths surfaces

Proper Use

Lightly remove only the sharp edge (do not remove excess material)
Deburr both sides of drilled holes when possible
Smooth cut ends of extrusion after cutting
Check parts by touch carefully after finishing

Common Mistakes

Over-deburring (making holes oversized)
Skipping internal hole edges
Leaving sharp edges on cut extrusion
Using excessive force that damages the part

Key Idea

Deburring is a small step that has a big impact. Removing sharp edges improves safety, ensures proper fastener fit, and increases overall build quality in FRC robots.

Hand Tools

Clamps

Clamps are holding tools used in FRC fabrication to secure parts together during assembly, drilling, or gluing. They act as temporary “extra hands” to keep parts aligned and stable.

Why Clamps Are Used

Clamps help:

Hold parts in position during drilling
Keep assemblies aligned while fastening
Prevent movement during marking or layout
Improve accuracy and repeatability

Common Types of Clamps in FRC

C-Clamps

Strong, rigid holding force
Best for heavy-duty metal-to-metal holding
Slower to adjust but very secure

Quick-Release (Trigger) Clamps

Fast to apply and remove
Good for repetitive assembly work
Moderate holding strength

Bar Clamps

Used for larger assemblies or long parts
Provide even pressure across surfaces
Useful for aligning long extrusion pieces

Proper Use

Ensure clamp pressure is applied evenly
Place clamps near the work area without blocking drill paths
Check alignment before fully tightening
Use protective padding if needed to avoid marking parts

Common Mistakes

Over-tightening and bending parts
Clamping without checking alignment first
Blocking access to drill or tool paths
Using the wrong clamp type for the job

Key Idea

Clamps improve accuracy and safety by holding parts in place during fabrication. Proper clamp selection and placement are essential for consistent, high-quality FRC builds.

Drilling

How to drill.

Drilling

Drill Bit Sizes

Selecting the correct drill bit size is important for proper fastener fit, tapping, and hole accuracy in FRC fabrication.

Common FRC Drill Bit Sizes

Drill Bit	Common Use
#43 (0.089")	Tap drill for 4-40
#36 (0.106")	Tap drill for 6-32
#21 (0.159")	Tap drill for 10-32
#7 (0.201")	Tap drill for 1/4-20
1/8"	Rivets and small hardware
3/16"	Large rivets
13/64"	Clearance hole for 10-32
17/64"	Clearance hole for 1/4-20

Tap Drill vs. Clearance Drill

Tap Drill

A tap drill creates the correct size hole for cutting threads with a tap.

Example:

A 10-32 screw uses a #21 drill bit before tapping.

Clearance Drill

A clearance hole allows a fastener to pass through freely.

Example:

A 10-32 bolt typically uses a 13/64" clearance hole.

Best Practices

Verify the required drill size before drilling.
Use a center punch to prevent drill wandering.
Deburr holes after drilling.
Label commonly used bits to prevent mistakes.

Common Mistakes

Using a clearance hole when tapping is required.
Selecting the wrong drill bit size.
Drilling oversized holes.
Forgetting to deburr the finished hole.

Key Idea

Using the correct drill bit size ensures proper fastener fit, accurate hole placement, and reliable assemblies on an FRC robot.

Drilling

Pilot Holes

A pilot hole is a small hole drilled before the final hole size. Pilot holes improve accuracy and make larger holes easier to drill.

Why Use a Pilot Hole?

Pilot holes help:

Keep the drill bit centered
Reduce drill bit wandering
Improve hole accuracy
Reduce cutting force on larger drill bits
Produce cleaner holes

When to Use Pilot Holes

Pilot holes are especially useful when:

Drilling large holes
Drilling thick material
Working with precise hole locations
Using step-up drill sizes

Small holes, such as rivet holes, often do not require a pilot hole.

Typical Process

Mark the hole location.
Center punch the hole.
Drill a small pilot hole (such as 1/8").
Drill the final hole size.

Best Practices

Always center punch before drilling.
Keep the drill perpendicular to the material.
Use steady pressure and let the drill bit cut.
Deburr the finished hole.

Key Idea

Pilot holes improve drilling accuracy and make larger holes easier to produce. Taking the extra step can prevent misplaced holes and improve part quality.

Drilling

Drill Presses vs. Hand Drills

Both drill presses and hand drills are commonly used in FRC fabrication. Choosing the correct tool depends on the accuracy, size, and location of the hole.

Drill Press

A drill press holds the drill bit perpendicular to the material and provides precise control.

Advantages:

Highly accurate hole placement
Straight, perpendicular holes
Better for large or repeated holes
Safer for precision work

Best for:

Drilling plates
Tapping preparation holes
Multiple identical parts
High-accuracy hole locations

Hand Drill

A hand drill is portable and can be brought directly to the workpiece.

Advantages:

Portable and versatile
Fast setup
Useful on large assemblies
Can reach locations that do not fit on a drill press

Best for:

Robot repairs
Large assemblies
Quick modifications
Field or pit work

Safety

Always secure the material before drilling.
Wear safety glasses.
Remove chips and debris frequently.
Keep hands away from the drill bit.

Key Idea

Use a drill press when accuracy is most important and a hand drill when portability and accessibility are needed. The right tool depends on the job.

Drilling

Proper Feed Pressure and Speed

Proper feed pressure and drill speed are important for producing clean holes, extending tool life, and improving safety.

Feed Pressure

Feed pressure is the amount of force applied while drilling.

Apply steady, consistent pressure
Let the drill bit do the cutting
Do not force the drill through the material

Too much pressure can:

Break drill bits
Create oversized holes
Cause the drill to grab the material

Too little pressure can:

Generate excessive heat
Dull the drill bit
Produce poor surface finish

Drill Speed

Different materials and bit sizes require different speeds.

Small drill bits: Higher speeds
Large drill bits: Lower speeds
Aluminum: Moderate to high speeds

If the drill bit becomes extremely hot or produces poor chips, adjust the speed or feed pressure.

Signs of Proper Drilling

Continuous metal chips are produced
The drill cuts smoothly
Minimal vibration occurs
The hole is clean and round

Common Mistakes

Pushing too hard on the drill
Running large bits at high speed
Using excessive force when the bit becomes dull
Continuing to drill if the material is vibrating or moving

Key Idea

Use steady pressure and the proper drill speed for the material and bit size. Let the drill bit cut the material rather than forcing it through.

Riveting

A more advanced method of mating parts.

Riveting

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.

Riveting

Blind Rivets

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

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

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

Riveting

Sizes 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.

Riveting

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

Insert rivet into the drilled hole
Place rivet gun nose onto the mandrel
Squeeze or activate the tool
The mandrel is pulled, expanding the rivet
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.

Riveting

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.

Tapping Threads

How to make the threads for bolts to tap into.

Tapping Threads

General Overview

A tapped hole is a drilled hole that has internal threads cut into it so a screw or bolt can be directly threaded into the material without using a nut.

How It Works

A hole is drilled to a specific size (called a tap drill size)
A tool called a tap is used to cut threads inside the hole
A screw or bolt can then be threaded directly into the material

Why FRC Teams Use Tapped Holes

Tapped holes are useful because they:

Eliminate the need for a nut on the back side
Save space in tight assemblies
Reduce part count
Allow clean, compact mounting points

Common Applications

Mounting sensors
Attaching small brackets
Light structural connections
Situations where access to the back side is impossible

Limitations

Threads can strip if over-tightened
Not as strong as bolt-and-nut connections in high-load areas
Requires correct drill size and careful tapping

Best Practice

Always use the correct tap drill size
Start tapping slowly and keep it straight
Use cutting fluid when possible
Avoid over-tightening screws in aluminum

Key Idea

A tapped hole allows a screw to thread directly into a material, making it useful for compact and lightweight FRC designs, but it must be used carefully to avoid stripping threads.

Tapping Threads

Tap Drill Hole Sizes

Page — Tap Drill Hole Sizes (10-32 and 1/4-20)

Before tapping a hole, the correct drill bit diameter must be used. The tap drill is slightly smaller than the final thread size so the tap can cut threads into the material properly.

10-32 Tap Holes

For a 10-32 thread, the correct tap drill size is:

#21 drill bit (0.159")

This size provides:

Enough material for strong threads
Proper engagement for aluminum tapping
Reduced risk of stripping when used correctly

1/4-20 Tap Holes

For a 1/4-20 thread, the correct tap drill size is:

#7 drill bit (0.201")

This size provides:

Strong, coarse threads suitable for higher loads
Better durability in structural applications
Lower chance of thread failure compared to tighter fits

Why Correct Hole Size Matters

Using the wrong tap drill size can cause:

Weak or stripped threads
Difficulty starting the tap
Broken taps inside the material
Poor fastener holding strength

Best Practice

Always verify drill size before tapping
Use a center punch before drilling
Drill perpendicular to the surface
Use cutting fluid when tapping aluminum

Key Idea

Tap drill size determines thread strength and reliability. In FRC, #21 for 10-32 and #7 for 1/4-20 are standard sizes that ensure strong, consistent threaded holes.

Tapping Threads

Using a Hand Tap

A hand tap is a tool used to cut internal threads into a drilled hole so that a screw or bolt can be directly fastened into material such as aluminum.

Before Tapping

Drill the correct tap drill size hole (example: #21 for 10-32, #7 for 1/4-20)
Deburr the hole to remove sharp edges
Secure the part so it cannot move
Select the correct tap size

How to Use a Hand Tap

Insert the tap into a tap handle
Align the tap perpendicular to the hole
Apply gentle downward pressure and begin turning clockwise
After 1–2 turns, continue turning slowly with steady pressure
Every few turns, reverse slightly to break chips
Continue until the desired thread depth is reached

Key Technique

Keep the tap straight at all times
Do not force the tap if it becomes difficult to turn
Use cutting fluid when possible to reduce friction and improve thread quality

Common Mistakes

Starting the tap at an angle
Forcing the tap (can break it easily)
Not backing out to clear chips
Using the wrong tap drill size

Key Idea

A hand tap must be started carefully and kept straight. Most tap failures come from misalignment or forcing the tool instead of allowing it to cut gradually.

Tapping Threads

Cutting Fluid

Cutting fluid is a lubricant used during drilling and tapping to reduce friction and heat.

Why It’s Used

Reduces heat buildup
Lowers friction on tools
Helps produce cleaner threads
Extends drill and tap life

When to Use It

Tapping aluminum (10-32, 1/4-20)
Drilling larger or deep holes
When tools start to feel hot or resist cutting

How to Use It

Apply a small amount to the hole or tool
Reapply if needed during cutting
Keep it light—don’t overuse

Key Idea

Cutting fluid makes drilling and tapping easier and safer by reducing heat and friction, especially in aluminum.

Tapping Threads

Preventing Broken Taps (Conclusion)

Preventing broken taps comes down to control, preparation, and patience.

Key Habits

Drill the correct tap drill size before starting
Keep the tap perfectly straight
Use cutting fluid to reduce friction
Turn slowly and apply light, steady pressure
Back the tap out often to clear chips

What to Avoid

Forcing the tap when resistance increases
Starting at an angle
Skipping chip clearing
Rushing the process

Final Idea

Most tap failures are caused by technique, not the material. Careful alignment, steady motion, and chip control make tapping reliable and safe in FRC fabrication.

Materials

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

Materials

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:

High strength and stiffness
Excellent machinability
Holds tapped threads well
Good balance of weight and durability

Typical use:

Structural extrusion (1x1, 2x1, 2x2)
Drivetrain frames
Tapped mounting points

5052 Aluminum

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

Properties:

Very ductile (bends without cracking)
Not ideal for tapped holes
Good fatigue resistance in sheet form
Easier to form than 6061

Typical use:

Custom plates and gussets
Sponsor-cut sheet parts
Bent or formed panels

7000 Series Aluminum (e.g., 7075)

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

Properties:

Very high strength-to-weight ratio
Stronger than 6061-T6
Lower corrosion resistance unless treated
More expensive and more sensitive to machining conditions

Typical use:

High-performance custom components
Lightweight but high-load structural parts
Specialized drivetrain or mechanism elements

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:

High-strength drivetrain components
Sprockets, hubs, and adapters
Gearbox plates and structural side plates
Shaft interfaces and high-load rotating assemblies

Why vendors use it:

Allows lighter parts without sacrificing strength
Handles repeated high torque loads better than 6061
Improves durability in high-performance mechanisms
Enables thinner, more compact designs while maintaining strength

6061 vs 5052 vs 7000 Series

5052 → flexible sheet metal, easy forming
6061 → standard structural extrusion, balanced performance
7000 series → high-performance COTS and custom components with maximum strength

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.

Materials

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:

Has very high strength
Resists bending and deformation
Handles high loads and impacts well
Works well for shafts and fasteners

Common Types of Steel in FRC

Mild Steel

Easy to machine and cut
Used for simple brackets or mounts
Heavier than aluminum

Hardened Steel

Very strong and wear-resistant
Used for shafts, axles, and gears
Difficult to machine without proper tools

Common Applications

Drive shafts and axles
Bearings and wear surfaces
High-load mounting hardware
Gearboxes and transmission components

Limitations

Much heavier than aluminum
Harder to machine and drill
Can slow down robot performance if overused
Requires stronger tools and more effort to modify

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.

Materials

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:

Is very impact resistant (won’t easily shatter)
Is lightweight compared to metal
Can be cut, drilled, and bent easily with heat
Provides visibility through clear panels

Common Applications

Robot bumpers backing plates
Protective guards over mechanisms
Electrical covers and shields
Intake guards and anti-interference panels
Field-safe transparent barriers on mechanisms

Properties to Know

Flexible: can bend without cracking
Durable: absorbs impacts without breaking
Machinable: can be drilled and cut with proper tools
Sensitive to heat: can melt or deform if overheated

Important Handling Notes

Use sharp drill bits to prevent cracking
Avoid high drill speed and excessive pressure
Support the material when drilling near edges
Do not overtighten fasteners (can cause cracking over time)

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.

Materials

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:

Polypropylene base material
Glass fiber reinforcement

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

Why FRC Teams Use SRPP

SRPP is used because it:

Is lightweight compared to aluminum
Has good stiffness for a plastic material
Is impact resistant and durable
Does not crack as easily as brittle plastics
Is easy to cut and machine

Common Applications

Robot structural plates
Mounting plates and brackets
Intake side plates
Lightweight gearbox or mechanism plates
Non-metal structural components

Manufacturing Notes

Don't cut it with the CNC, use the laser cutter instead.
Drills cleanly with proper speed and sharp bits if you heat up the edges with the flamethrower afterwards.
Works well with bolts and rivets if you use large washers

Limitations

Not as strong as aluminum in high-load structural areas
Can flex under heavy drivetrain loads
Edge quality matters for strength (avoid rough cuts)

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.

Materials

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:

Is strong and relatively stiff for its weight
Is easy to cut, drill, and shape with basic tools
Holds fasteners reasonably well
Is inexpensive and widely available

Common Use in FRC

Plywood is primarily used as bumper backing, where it:

Provides a rigid structure for bumper assemblies
Helps maintain bumper shape during impacts
Supports mounting hardware that attaches bumpers to the robot frame

Material Notes

Typically 3/4" thick in FRC applications
Grain layers are oriented for strength in multiple directions
Works best when edges are sealed or protected

Limitations

Can crack or splinter if overloaded or poorly drilled
Heavier than many modern composite materials
Sensitive to moisture if left unsealed

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.

Materials

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:

PLA → PETG → ABS → Nylon → TPU

As you move right:

Parts become tougher and more impact-resistant
Flexibility increases (until TPU)
Printing difficulty generally increases
Heat and fatigue resistance improve

Rigid vs. Tough vs. Flexible

PLA (Rigid, easy, brittle)

Most rigid but least durable
Breaks suddenly under impact
Best for prototypes and fit checks
➡️ Baseline material

PETG (Tough, slightly flexible)

Similar stiffness to PLA but much tougher
Absorbs impacts instead of cracking
Good “default functional” material
➡️ Step up in durability from PLA

ABS (Tough + heat resistant)

Similar toughness to PETG but better heat resistance
More stable in warmer environments
Warps more easily when printing
➡️ Functional + environment-resistant upgrade

Nylon (Very tough, wear-resistant, flexible)

Much more impact resistant than ABS/PETG
Excellent fatigue resistance (bending repeatedly)
Lower stiffness than PLA/ABS but far more durable
➡️ Best for moving/wear parts

TPU (Flexible, elastic)

Completely different behavior from others
Bends, compresses, and returns to shape
Absorbs impact instead of resisting it
➡️ Used when flexibility is the goal

How They Compare in Use

PLA: “Does it fit?” prototypes
PETG/ABS: Real robot parts with moderate load
Nylon: High-stress or moving parts
TPU: Contact, grip, or shock absorption

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.

Materials

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

High strength and stiffness
Excellent machinability
Holds tapped threads well
Maintains shape under load with minimal flex
Can be anodized for corrosion resistance

5052 Aluminum

High ductility (bends without cracking easily)
Lower strength than 6061-T6 in rigid structures
Very good fatigue resistance in sheet form
Poor thread-holding capability compared to 6061
Excellent for forming and sheet fabrication

Polycarbonate

Extremely high impact resistance (does not shatter)
Flexible and can bend significantly before failure
Transparent, allowing visibility through panels
Sensitive to heat during machining
Crack-resistant compared to brittle plastics like acrylic

SRPP (Glass-Filled Polypropylene)

Lightweight with moderate stiffness
High vibration damping compared to metals
More rigid than standard plastics due to glass fill
Low density relative to aluminum
Good fatigue resistance in sheet applications

Steel

Very high strength and hardness
Excellent wear resistance
High density (heavy compared to aluminum)
Maintains shape under extreme loads
Can be heat-treated for increased hardness

Plywood

Cross-laminated structure resists splitting
Good stiffness for its weight
Anisotropic (strength depends on grain direction)
Absorbs impact energy without immediate fracture
Sensitive to moisture and environmental conditions

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.

Materials

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:

1/16"
1/8"
3/16"
1/4"
3/8"
1/2"

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

How Thickness Affects Strength

1/16"

Very lightweight
Low stiffness
Easily flexes under load
Best for non-structural covers or light panels

1/8"

Common general-purpose thickness
Good balance of stiffness and weight
Widely used for gussets and light structural plates

3/16"

Noticeably stiffer than 1/8"
Much better resistance to bending and vibration
Used when higher structural rigidity is needed

1/4"

High stiffness and strength
Strong resistance to bending and impact
Significant weight increase
Used for structural or high-load plates

3/8"

Very rigid
Used in specialized high-load or mounting applications
Often heavier than necessary for most robot mechanisms

1/2"

Extremely stiff and strong
Minimal flex even under heavy loads
Very heavy for robotics use
Typically reserved for specialty or extreme-load components

Why Teams Pocket Parts

Reduces weight without fully reducing stiffness where it matters
Maintains strength along outer load paths while removing unnecessary material
Improves robot performance by lowering overall mass
Allows designs to stay structurally efficient instead of uniformly overbuilt

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.

FRC Hardware Standards

Learn about all the hardware a typical FRC robot consists of.

FRC Hardware Standards

10-32 Hardware

10-32 is the most common fastener size used in FRC. It provides a good balance of strength, weight, and ease of use, making it suitable for many robot assemblies.

What Does 10-32 Mean?

#10 refers to the screw diameter.
32 refers to the number of threads per inch (TPI).

This makes 10-32 a fine-thread fastener that provides good holding strength in aluminum.

Common Hardware

10-32 hardware includes:

Socket head cap screws
Button head screws
Nylock nuts
Washers
Tapped holes in aluminum

Common Lengths

Typical lengths used in FRC include:

1/2"
3/4"
1"
1-1/4"
1-1/2"

The correct length should allow full thread engagement without excessive exposed threads.

Typical Tools

5/32" hex key or T-handle
3/8" wrench or socket for nuts
#21 drill bit for tap holes
13/64" drill bit for clearance holes

Why FRC Teams Use It

Strong enough for most robot assemblies
Easy to tap into aluminum
Widely available from FRC vendors
Compatible with many commercial robot components

Key Idea

10-32 hardware is the standard fastener system for many FRC robots because it provides reliable strength while remaining compact and easy to work with.

FRC Hardware Standards

1/4-20 Hardware

1/4-20 hardware is commonly used in FRC for high-load applications where additional strength is needed. The larger diameter provides greater thread engagement and improved resistance to stripping.

What Does 1/4-20 Mean?

1/4 refers to the major diameter of the screw (0.250")
20 refers to the number of threads per inch (TPI)

This makes 1/4-20 a coarse-thread fastener that is durable and well-suited for structural applications.

Common Hardware

1/4-20 hardware includes:

Socket head cap screws
Button head screws
Nylock nuts
Washers
Tapped holes in aluminum

Common Lengths

Typical lengths used in FRC include:

1/2"
3/4"
1"
1-1/4"
1-1/2"
2"

The correct length should allow full thread engagement without excessive exposed threads.

Typical Tools

3/16" hex key or T-handle
7/16" wrench or socket for nuts
#7 drill bit for tap holes
17/64" drill bit for clearance holes

Why FRC Teams Use It

Stronger than 10-32 hardware
Better for high-load applications
Less likely to strip in aluminum
Common for structural and mounting applications

Key Idea

1/4-20 hardware is used when additional strength and durability are needed. Its larger size makes it ideal for high-load joints and structural connections.

FRC Hardware Standards

Shafts

Shafts are rotating elements used to transmit torque through a robot’s mechanisms. In FRC, different shaft geometries are used depending on how securely components must transfer motion and how much load the system experiences.

Common Shaft Types

1/2" Hex Shaft

Most common FRC shaft type
Torque is transmitted through flat faces
No slipping when used with matching hubs
Easy to assemble and align

3/8" Hex Shaft

Smaller, lighter hex shaft option
Used in compact or low-load mechanisms
Easier to package in tight designs
Lower torque capacity than 1/2" hex

1/2" Round Shaft

Smooth cylindrical shaft
Requires keys, pins, or set screws for torque transfer
Can slip if not properly constrained
Used when free rotation or simple pivots are needed

Spline XL Shaft System

Spline XL is a high-torque shafting system used in FRC for demanding applications.

Key Features:

Multiple splines (teeth) around the shaft
Very high torque capacity
Prevents slippage under heavy load
Allows precise, repeatable component alignment

Why Teams Use It:

Handles extreme drivetrain loads
More robust than hex shafts in high-stress systems
Reduces wear from repeated high-torque cycles
Improves long-term reliability

How They Relate

Round shaft → simplest, lowest torque transfer (needs retention features)
3/8" hex → compact, moderate torque, space-saving option
1/2" hex → standard balance of strength and usability
Spline XL → maximum torque capacity and reliability

As load requirements increase, teams typically move from round → smaller hex → 1/2" hex → spline-based systems.

Common Applications

Drivetrains (1/2" hex, Spline XL)
Intakes and rollers (3/8" and 1/2" hex)
Elevators and arms (1/2" hex, Spline XL)
Light pivots and mechanisms (round shaft)

Key Idea

Shaft selection depends on torque, packaging, and reliability needs. 3/8" hex is a compact option, 1/2" hex is the standard, round shafts require additional retention, and Spline XL is used when maximum torque capacity and durability are required.

FRC Hardware Standards

Bearings and Bushings

Bearings and bushings support rotating shafts and reduce friction between moving parts. They are essential components in nearly every FRC mechanism.

Bearings

Bearings use rolling elements, typically balls, to allow shafts to rotate with very low friction.

Advantages:

Very low friction
Smooth rotation
High efficiency
Excellent for high-speed applications

Common FRC uses:

Drivetrains
Rollers and intakes
Arms and elevators
Gearboxes

Bushings

Bushings use a smooth surface that the shaft slides against rather than rolling elements.

Advantages:

Simple and inexpensive
Lightweight
Resistant to dirt and debris
Compact design

Common FRC uses:

Low-speed pivots
Lightly loaded mechanisms
Simple rotating joints

Common Bearing Sizes

Typical FRC bearings include:

1/2" hex bearings
1/2" round bearings
Flanged bearings

Bearings are often press-fit into plates, tubes, or bearing blocks.

Bearing vs. Bushing

Bearing: lower friction, higher performance, higher cost
Bushing: simpler, cheaper, and better for low-speed applications

Key Idea

Bearings provide smooth, efficient rotation for most FRC mechanisms, while bushings offer a simple solution for lower-speed or lower-load applications. Choosing the correct support method improves reliability and reduces wear.

FRC Hardware Standards

Plastic Washers

Plastic washers are low-friction spacing components commonly used in FRC to reduce wear, prevent metal-on-metal contact, and fine-tune alignment in assemblies. West Coast Products (WCP) offers commonly used versions designed for FRC mechanisms.

What They Do

Plastic washers are placed between moving or clamped components to:

Reduce friction between metal parts
Prevent scratching or galling of aluminum surfaces
Act as precise spacing shims
Improve smoothness in rotating assemblies

Why Teams Use Them

Compared to metal washers, plastic washers:

Are lighter
Reduce wear on aluminum and steel parts
Provide smoother sliding surfaces
Help eliminate binding in tight assemblies

Common Applications

Shaft assemblies with gears, sprockets, or pulleys
Bearing stacks and spacing control
Pivot joints in arms or linkages
Low-friction interfaces in sliding mechanisms

Material Properties

Plastic washers (such as those from WCP) typically:

Have low friction surfaces
Compress slightly under load for fine adjustment
Do not corrode or seize like metal-on-metal contact
Wear faster than metal but are easily replaceable

Best Practices

Use plastic washers where parts rotate or slide against each other
Avoid over-compressing them in high-load structural joints
Combine with proper spacers for precise alignment
Replace if they become excessively worn or deformed

Key Idea

Plastic washers are used in FRC to reduce friction and wear while improving spacing accuracy in moving assemblies, making mechanisms smoother and more reliable over time.

FRC Hardware Standards

Standoffs

Standoffs are rigid spacers with threaded ends or through-holes used to separate and support two parallel components at a fixed distance. They are commonly used in FRC to build compact, lightweight assemblies.

What They Do

Standoffs:

Maintain a fixed distance between plates or components
Provide structural support without adding bulky brackets
Allow fasteners to pass through or thread into both ends
Help keep assemblies rigid and aligned

Common Types

Threaded standoffs: Threads on both ends for bolting into components
Through-hole standoffs: Bolts pass through the entire length
Hex standoffs: Easier to grip with a wrench during installation

Common Applications

Electronics mounting plates
Sensor and controller stacking
Gearbox and mechanism spacing
Lightweight structural supports between plates
Compact multi-layer assemblies

Materials

Aluminum (most common in FRC)
Steel (higher strength, heavier)
Plastic (light-duty or electrical isolation)

Aluminum is preferred for most mechanical applications due to its strength-to-weight ratio.

Best Practices

Use the correct length to avoid preloading or flexing parts
Ensure threads are fully engaged on both ends
Avoid over-tightening, which can strip threads in softer materials
Combine with washers when needed for surface protection

Key Idea

Standoffs create precise, rigid spacing between components, allowing FRC teams to build compact and organized assemblies while maintaining strength and alignment.

FRC Hardware Standards

Gussets

Gussets are flat structural plates used to reinforce joints between two or more components, typically at corners or intersections of extrusion in FRC robots.

Purpose

Gussets:

Strengthen 90° and angled joints
Reduce flex in structural frames
Distribute load across multiple fasteners
Improve rigidity without adding much weight

Custom Gussets

Custom gussets are designed by teams and usually cut from sheet material.

Common materials:

5052 aluminum (most common)
Polycarbonate (for light-duty or flexible use)
SRPP (for lightweight structural applications)

Characteristics:

Fully customizable geometry
Can be optimized for weight and packaging
Require CAD, machining, or sponsor manufacturing (laser/waterjet/CNC)

Vendor Gussets (WCP and Similar Suppliers)

Vendor gussets are pre-designed and pre-cut parts from suppliers such as West Coast Products.

Characteristics:

Standardized hole patterns (often 0.5" spacing compatible)
Fast to integrate into designs
Consistent strength and manufacturing quality
Reduce design and fabrication time

Typical features:

Pre-drilled patterns for 1/2" or 1x1 extrusion
Multiple angle options (90°, 45°, L-brackets, etc.)
Lightweight pocketed designs

When to Use Each

Custom gussets → when optimizing weight, packaging, or unique geometry
Vendor gussets → when speed, simplicity, and reliability are more important

Key Idea

Gussets reinforce structural joints in FRC robots. Custom gussets provide maximum design flexibility, while vendor gussets offer fast, reliable, and standardized solutions for common structural connections.