Aluminum

FRCAluminum teamsis commonly use two typesone of aluminum:the 6061most andimportant 5052.materials Theyin lookFRC. similarDifferent butaluminum areseries used forhave very different purposesstrengths, machining behavior, and real-world use in robot construction.components.

6061-T6 Aluminum

6061-T6 is the most common structural aluminumextrusion extrusionmaterial used in FRC.

Properties:

• High strength and stiffness
• Excellent for machining and tappingmachinability
• Holds tapped threads well
• CommonGood inbalance standardizedof extrusionsweight (likeand 1x1, 2x1, 2x2 tubing)durability

BestTypical uses:use:

• Robot frames and drivetrains
• Structural extrusion systems(1x1, 2x1, 2x2)
• Drivetrain frames
• Tapped holes for mounting mechanisms
• Load-bearing assembliespoints

5052 Aluminum

5052 is most commonly used foras custom cut sheet metal platesstock, oftenin provided by sponsors or local suppliers.FRC.

Properties:

• MoreVery flexibleductile and(bends bendablewithout than 6061
• Excellent for sheet metal formingcracking)
• Not ideal for tapped threadsholes
• ResistantGood fatigue resistance in sheet form
• Easier to crackingform whenthan bent6061

BestTypical uses:use:

• Custom gussetsplates and bracketsgussets
• Sponsor-cut platessheet parts
• Panels,Bent covers,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 guardsmore sensitive to machining conditions

Typical use:

• High-performance custom components
• Lightweight but high-load structural sheetparts
• 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 (Quickvs Comparison)7000 Series

• 6061-T6 → extrusion, rigid, machinable, structural
• 5052 → flexible sheet metal, bendable,easy laser/waterjetforming
cut
• 6061 plates→ standard structural extrusion, balanced performance
• 7000 series → high-performance COTS and custom components with maximum strength

Key Idea

6061-T6Most isFRC primarilyrobots usedare forbuilt extrudedfrom structural6061 tubing,extrusion whileand 5052 issheet, usedbut for7000 customseries sheetaluminum metalappears plates,frequently oftenin cutCOTS bycomponents sponsors.from Choosingvendors thelike correctWest materialCoast improvesProducts bothbecause strengthit enables stronger, lighter, and manufacturabilitymore incompact FRChigh-performance designs.parts.