Fabrication Safety How to maintain safety throughout your mechanical career. Safety Glasses 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. 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. 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. 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! 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 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. 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 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. 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 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) 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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. 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.