Aluminum Types (6061, 5052)

FRC teams commonly use two types of aluminum: 6061 and 5052. They look similar but are used for very different purposes in robot construction.

6061-T6 Aluminum

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

Properties:

• High strength and stiffness
• Excellent for machining and tapping
• Holds threads well
• Common in standardized extrusions (like 1x1, 2x1, 2x2 tubing)

Best uses:

• Robot frames and drivetrains
• Structural extrusion systems
• Tapped holes for mounting mechanisms
• Load-bearing assemblies

5052 Aluminum

5052 is most commonly used for custom cut sheet metal plates, often provided by sponsors or local suppliers.

Properties:

• More flexible and bendable than 6061
• Excellent for sheet metal forming
• Not ideal for tapped threads
• Resistant to cracking when bent

Best uses:

• Custom gussets and brackets
• Sponsor-cut plates
• Panels, covers, and guards
• Lightweight structural sheet parts

6061 vs 5052 (Quick Comparison)

• 6061-T6 → extrusion, rigid, machinable, structural
• 5052 → sheet metal, bendable, laser/waterjet cut plates

Key Idea

6061-T6 is primarily used for extruded structural tubing, while 5052 is used for custom sheet metal plates, often cut by sponsors. Choosing the correct material improves both strength and manufacturability in FRC designs.