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.