Rivets, as important mechanical fasteners, remain popular in modern manufacturing industries due to their simplicity and robustness. So, what exactly are rivets? What functions do they serve? Moreover, with emerging industries such as new energy, robotics, and automation developing increasingly rapidly, how should you choose the right rivets for your needs?
This guide covers common rivet types, applications, materials, and many other aspects, enabling you to gain a comprehensive understanding of rivets and thereby develop an appropriate rivet selection strategy.
What Is a Rivet?
A rivet is a mechanical fastener that connects two or more parts by deforming itself. It is typically used to form permanent joints. Unlike screws or bolts, rivets do not have threads for locking and are not designed for repeated assembly and disassembly. They are well-suited for use with thin sheets or coated plates.
Parts of a Rivet and Key Terminology
Although different types of rivet structures may vary slightly, most rivets consist of a head, shank, and tail. Below, I will explain in detail each part of the rivet structure for you.
Factory Head
Factory head, which we also call manufactured head, is the head that is already formed during rivet production. After the rivet is installed, the factory head will fit against one side of the workpiece and work together with the shop head or the blind side bulge formed on the other side to clamp the materials.
Factory head can take forms such as round head, flat round head, countersunk head, or large flange head. Moreover, different head shapes will also affect the bearing surface area, installation space, etc., of the rivet.
Shank or Rivet Body
The shank is the cylindrical part of a solid rivet that passes through the hole in the part. In blind rivets, this part is also called the rivet body. The shank diameter must be correctly matched to the installation hole. If the hole is too large, the rivet will become loose. If the hole is too small, the rivet will not be able to be inserted.
Tail
The tail is the end opposite to the rivet and factory head, and it is also the area where deformation occurs during installation. Sufficient forming length must be left at the tail end. If the length is insufficient, a complete rivet head may not be formed. If the length is too long, the rivet may bend or crack. Therefore, the specific reserved length needs to be determined based on your application.
Shop Head
Shop Head, also known as upset head or field-formed head, is the second head formed by plastic deformation of the tail after rivet installation.
The shape of the shop head reflects the quality of the riveting. A rivet head that is too small may indicate insufficient rivet length or inadequate riveting. If the rivet head is too flat, cracked, or obviously eccentric, it may be related to an excessively long rivet or excessive installation force. Blind rivets typically form a blind-side bulb, and the shop head determination method for solid rivets should not be directly applied.
Mandrel
Mandrel is a rod-shaped component inside a blind rivet. During installation, the rivet pulling tool grips and pulls the mandrel, causing the mandrel head to compress the tail of the rivet body. This forces the rivet body to expand or fold on the blind side, thereby clamping the parts together.
Grip Range
Grip range refers to the total thickness range of materials that rivets can properly connect. When calculating, you need to add up the actual thickness of all gripped layers, but usually do not include the factory head, washers, and components not within the clamping area. It is worth noting that the grip range is particularly applicable for blind rivet selection.
How Does Riveting Work?
The structure of rivets looks simple, but it is one of the most stable fastening methods in metal machining. As for exactly how do rivets work. Don’t worry, I’ll tell you the specific steps next. The typical riveting process can be divided into the following steps:
Machine and Align Mounting Holes
First, you need to machine holes on the connecting parts and keep the hole positions aligned using fixtures or locator pins.
Insert Rivet
You must insert the rivet through all layers of material. The rivet’s factory head must lie flush with the surface of the workpiece. Additionally, the diameter, length, or grip range of the rivets must match the hole diameter and the total thickness of the material.
Apply Installation Force
Based on the rivet type, you can apply force to the rivet tail or mandrel using rivet guns, hammers, presses, or pull rivet tools. The tools must also maintain alignment with the rivet axis to avoid rivet tilting.
Causes Plastic Deformation of The Rivet Tail
Installation force shortens the rivet tail and expands it radially, forming a shop head or blind-side bulb. The final size is approximately 1.5 times the original size.
Check Riveting Results
It’s not enough to just install the rivets. You also need to inspect the riveting results, including verifying that the heads are flush, the tails are fully formed, and the joints are secure. At the same time, you should check if the workpiece has any dents or cracks.
Main Types of Rivets
When it comes to rivet types, there are so many of them. Each rivet type has its own unique structure and purpose.
Solid Rivets
Solid rivets are the most common type of rivets, primarily consisting of a solid shank and a factory head. This type of rivet is simple to use and highly reliable. It can be used with 100-degree countersunk heads or round universal rivet heads.
In addition, solid rivets can form stable hole wall fits, making them very suitable for applications in aerospace structures, heavy vehicles, machinery equipment, and other industries.
Blind or Pop Rivets
A blind rivet consists of a hollow rivet body and a mandrel, and is installed from only one side of the joint. When you pull the rivet’s mandrel with a rivet tool, the rivet body expands on the back side to form a blind-side bulb, and the mandrel then breaks off at the designed location.
This type of rivet is commonly found in parts made from sheet metal fabrication, such as custom enclosure, pipes, cabinets, and automotive parts. You have probably seen this type of rivet in various assembly or maintenance scenarios.
Some common blind rivets include:
- Pull-mandrelrivet: A special double countersunk blind rivet. The mandrel head of this rivet will not break and can provide stable clamping force.
- Threaded rivets: Also known as blind rivet nuts or threaded inserts. Threaded rivets are divided into two types: standard and heavy-duty. The standard type can meet almost all blind riveting applications. Heavy-duty rivets have robust sidewalls and heads, making them more suitable for high-performance applications.
- Drive pin rivets: This type of blind rivet has a short mandrel protruding from the head. Since these rivets do not require drilling holes, they are more commonly used in construction and other applications where aesthetics are important.
Flush Rivets
Also known as countersunk rivets. Flush rivets feature a countersunk hole with a matching countersunk head. This type of rivet is mainly used on exterior surfaces, ensuring good appearance while also eliminating air resistance. Therefore, flush head rivets are well suited for aircraft exterior applications.
Structural Blind Rivets
A structural blind rivet is a blind riveting fastener designed for higher load, vibration, or fatigue requirements. Its installation principle is similar to that of ordinary blind rivets. However, structural blind rivets typically have a more robust rivet body and a specific mandrel locking structure.
This type of rivets are commonly used in industrial equipment, rail transit, automotive, and other industries.
Semi-Tubular Rivets
The shank of a semi-tubular rivet is solid, but its tail has an axial hole of a certain depth. The hole depth is usually about 1.12 times the diameter of the rivet shank.
During installation, its hollow tail curls or expands outwards to form a riveted head. Therefore, the forming force required for semi-tubular rivets is usually lower than that of solid rivets of the same size.
In addition, semi-tubular rivets are commonly used in hinges, brake components, ladders, home appliances and other fields.
Tubular Rivets
The shank of a tubular rivet is mostly hollow. Its tail end is usually installed by curling, flaring, or beading. This type of rivet has high ductility and is made from low-strength metals. Therefore, tubular rivets are widely used in electronic products, leather goods, luggage, and other light-duty components.
Common types of tubular rivets include:
- Compression tubular rivets: This type of rivet consists of two parts. They are mainly used for soft materials.
- Full tubular rivets: This type of rivet has deeper holes than semi-tubular rivets and usually has lower strength.
Self-Piercing Rivets
A self-piercing rivet is a type of semi-hollow rivet that typically does not require pre-drilled holes. This type of rivet requires no drilling or punching, with a chamfered end that can directly pierce through the upper material and expand radially within the lower material to form a mechanical interlock.
This type of rivet is suitable for automotive body, electric vehicle battery structures, and multi-material panels.
Drive Rivets
Drive rivets consist of a rivet body and a center pin. When you install this type of rivet, you need to first place the rivet into the pre-drilled hole, then use hammering or pressure to drive the center pin in, causing the tail of the rivet body to expand radially and lock inside the hole.
Drive pin rivets typically only require operation from one side and do not need pull rivet tools. Therefore, this type of rivet is suitable for nameplates, decorative panels, equipment nameplates, panels and other components. The entire installation process is also very simple.
Split Rivets
Split rivet is also called bifurcated rivet. Its shank tail is divided into two legs. When installing this rivet, its legs spread apart or curl outward after passing through the material, securing the parts with a larger expanded area.
This type of rivet is often more suitable for low-density materials such as leather, wood, cardboard, and fiberboard.
Rivet Types Comparison Table
| Rivet Type | Joint Accessibility | Pre-drilled Hole Required | Typical Application |
| Solid Rivet | Usually requires access from both sides | Required | High-reliability and load-bearing joints |
| Blind Rivet | Requires access from one side only | Required | General sheet metal, enclosed housings, and field assembly |
| Structural Blind Rivet | Requires access from one side only | Required | Higher load, vibration, or structural connections |
| Semi-Tubular Rivet | Usually requires access from both sides | Usually required | Hinges, mechanical components, and mass production assembly |
| Tubular Rivet | Usually requires access from both sides | Usually required | Light-load products and soft materials |
| Self-Piercing Rivet | Tooling must contact both sides | Usually not required (self-piercing, no through-hole) | Automotive and multi-material panels |
| Drive Rivet | Requires access from one side only | Usually required | Nameplates, panels, and light-duty assemblies |
| Split Rivet | Depends on installation method | Usually required for hard materials | Leather, wood, and fiberboard |
Common Rivet Materials
After discussing the types, let’s talk about which materials are suitable for processing into custom rivets. Moreover, the material of the rivet will directly affect the bearing capacity, forming force, corrosion resistance and service life of the joint. Therefore, when selecting rivets, material is also a factor that must be considered.
Aluminum Rivets
Aluminum rivets are prone to plastic deformation. When installing these rivets, the load applied to the thin sheets by the installation tool is also small. Therefore, weight-sensitive components such as aluminum plates and lightweight shells are very suitable for using aluminum rivets.
Carbon Steel Rivets
Carbon steel rivets are commonly used for industrial joints that require high mechanical strength while maintaining cost control. They are well-suited for use in steel brackets, machine housings, vehicle components, and more.
Additionally, the primary limitation of carbon steel is corrosion. However, galvanizing, nickel plating, or coating can improve its protective capabilities.
Stainless Steel Rivets
Stainless steel rivets are sturdy and durable, with excellent corrosion resistance. These rivets are well-suited for applications in humid, outdoor, food processing, and chemical environments.
But compared to aluminum rivets, stainless steel rivets of the same specification are usually more difficult to form during use.Therefore, when installing stainless steel rivets, you need to use the appropriate riveting tool, press, or riveting die.
Copper and Brass Rivets
Copper rivets have good ductility and conductivity, commonly used in electrical connections, roofing and decorative products. As for brass rivets, they are commonly used in instruments, furniture, luggage and consumer products with appearance requirements.
Rivets of both materials are very easy to form. When designing or selecting, you need to verify the specific grade according to your product requirements.
Monel Rivets
Monel is a type of nickel-copper alloy, primarily used in corrosive environments such as marine, chemical, and aerospace applications. This material has good corrosion resistance and mechanical properties.
Monel rivets have higher material costs and installation requirements, and are generally not used for ordinary low-load sheet metal applications.
Titanium Rivets
Titanium rivets offer excellent strength and corrosion resistance. Therefore, these rivets are suitable for industries with high performance requirements, such as aerospace, racing, and marine equipment.
However, titanium rivets are more expensive and have stricter requirements for forming and hole quality.
Advantages & Limitations of Rivets
Regarding the advantages and disadvantages of rivets, I believe this is also a topic that you are quite interested in. Especially when many people are making selections, they need to consider whether these characteristics of rivets meet their usage requirements.
Pros of Rivets
- Quick Installation: Rivets can be easily and quickly installed in seconds using pneumatic tools.
- Connection stability: Rivets form mechanical locking through plastic deformation, providing good connection stability.
- Cost-effective: Riveting installation is cost-effective, cheaper than bolted connections
- Good anti-vibration performance: After the rivets are correctly formed, they will not easily become loose due to vibration.
- Durable and robust: Solid rivets have excellent wear resistance and stress resistance performance.
- Material compatibility: Can connect different materials such as steel, aluminum, plastic and composite materials.
- Low thermal impact: The installation process of rivets does not produce a heat-affected zone.
- Versatile applications: Rivets can be manufactured in different types according to requirements to adapt to different applications.
Cons of Rivets
- Labor costs are relatively high.
- Riveting force may cause thin plates, plastics or composite materials to dent, crack and locally deform.
- The riveting process generates significant noise.
- Once rivets are riveted, they usually need to be drilled out, sawed off, or chiseled away to be removed.
- Small gaps are easily left between riveted joints.
What Is a Rivet Used For?
Due to the practicality and reliability of rivets, their range of application is very extensive. Below, I will introduce them to you one by one.
Aerospace
In the aerospace industry, a large number of rivets are used on aircraft fuselage skins, spars, wing panels and internal brackets. Properly installed solid rivets can form stable hole wall fits. Meanwhile, riveting can also ensure the structural integrity and strength of the aircraft, thereby reducing the aircraft’s weight.
Automotive
In automotive manufacturing, rivets can be used for body panels, brackets, doors, seat structures and electric vehicle battery housings. Self-piercing rivets are suitable for steel and aluminum sheets, while blind rivets and structural blind rivets are also suitable for vehicle maintenance and closed structures.
Sheet Metal
Sheet metal fabrication is one of the most common applications for blind rivets. Rivets can be used for cabinets, equipment housings, ducts, baffles, brackets and access panels. Standard blind rivets can meet the fastening requirements of most sheet metal parts.
Construction
Rivets are also widely used in the construction industry, such as metal roofing, curtain walls, drainage systems, signage, etc. These rivets can provide good connection stability.
Electronics and Appliances
At this moment, you look around and observe the electronic products or appliances in your home. You will surely discover that many electronic devices contain rivets.
Industrial Machinery
In the industrial sector, components such as equipment guards, brake parts, mechanical linkages, and cargo containers all utilize rivets. Additionally, industrial equipment typically needs to withstand impact and continuous vibration, so you also need to pay attention to issues such as hole wear, mandrel retention, and joint fatigue.
Marine Applications
Ships and marine equipment can use rivets to connect aluminum alloy plates, deck fittings, cabin brackets and external equipment. You can select aluminum, monel or specific stainless steel rivets according to specific usage requirements. In marine environments, the biggest problem for equipment is corrosion, so rivets must also be used in combination with coatings, isolation layers or sealants.
How to Choose the Right Rivet?
When choosing rivets, you cannot just look at diameter, length, or material, but should determine from multiple perspectives which rivet is truly more suitable for your needs. If you still have no idea at this point, you might as well refer to the several suggestions I’ve provided.
Check Access to the Joint
You first need to confirm whether the installation tool can access both sides of the joint. This is also the first step in determining the rivet type.
- Both sides accessible: You can consider solid rivet, semi-tubular rivet or tubular r
- Single-side operation only: You can prioritize blind rivet, structural blind rivet, drive rivet or rivet n
- Automated sheet connection: If the equipment can place punch and die on both sides of the parts, you can evaluate and use self-piercing r
Determine Material Thickness and Grip Range
You must measure the actual total thickness of all gripped material layers. For blind rivets, this thickness value must be within the grip range specified by the manufacturer.
Identify the Main Load
Riveted joints may be subjected to different loads. You need to select appropriate rivets based on the failure modes of the joints.
- Primarily shear loading: Solid rivet or structural blind rivet are typically more suitable.
- High axial tension present: You need to check rivet head retention, Mandrel locking and parent material pull-through capability.
- Peel loading present: You should adjust the joint structure to convert the load into shear or in-plane loading as much as possible.
Evaluate the Base Materials
The thickness, strength, hardness, and ductility of the base material will affect the forming of the rivet. Materials like thin aluminum sheets and plastics are easily pulled through by rivet heads, so you need to consider using large flange heads or washers.
Additionally, the rivet material should match the hardness of the base material. If the rivet is too hard, it may deform or crack the soft base material; if the rivet is too soft, it may shear, crush, or gradually loosen under load.
Consider Corrosion and Temperature
This point is very important. Moisture, salt spray, chemicals and temperature changes all affect rivet life. If your rivets need to be used outdoors or in corrosive environments, you need to select rivets with corrosion resistance based on the base material.
In addition, galvanic corrosion may also occur between dissimilar metals. You must pay close attention to this point as well.
Select the Appropriate Head Style
The head shape of rivets affects their bearing area, appearance, etc.
- Dome or round Head: High versatility
- Countersunk head: Used for housings, sliding surfaces, etc.,that require near-flush surfaces
- Large flange head: Suitable for thin plates, plastic, and other materials
Determine Whether Sealing Is Required
Standard open-type blind rivets do not have waterproof or airtight capabilities. If you need rivets with good airtightness, you can consider:
- Closed-end blind rivet
- Rivets with sealing washers
- Sealant or structural adhesive
- Joint design to prevent water retention
- Leak testing after installation
Match the Rivet to the Installation Tool
The installation tools you currently have must match the rivets. Manual rivet guns are suitable for small batches and smaller blind rivets. Pneumatic or hydraulic tools are more suitable for rivet connection products that require continuous production. For rivets like solid rivets and semi-tubular rivets, you need to use rivet guns and presses.
Confirm Maintenance Requirements
Standard rivets are generally permanent fasteners. When disassembling, they need to be drilled out or cut off. If the components require regular maintenance, replacement, or upgrades, screws, bolts, or Rivet Nuts would be more suitable for your needs.
Rivets vs Screws, Bolts, Welding, and Adhesives
Finally, I will provide a detailed comparison of the five types of connections: rivets, screws, bolts, welding, and adhesives, so that you can have a deeper understanding of them.
| Joining Method | Primary Load Transfer Mechanism | Disassembly | Joint Accessibility | Key Limitations |
| Rivets | Shank shear, bearing on hole wall, and head retention | Typically requires destructive removal | Blind rivets allow single-side installation; solid rivets typically require both-side access | Requires drilled holes; improper installation may cause loosening, pull-through, or sheet deformation |
| Screws | Thread engagement and clamping force | Repeatably removable | Self-tapping or tapped-hole types allow single-side installation | May loosen or strip; limited effective thread length in thin sheets |
| Bolts | Preload-induced clamping and friction, or shank shear and bearing on hole wall | Repeatably removable | Typically requires access to both sides, or a captive nut | Higher part count; requires installation clearance and torque control |
| Welding | Continuous material bonding through the weld | Generally not removable non-destructively | Depends on welding process and joint design | May cause distortion, residual stress, and heat-affected zones; limited by material weldability |
| Adhesives | Load distributed across a larger bonded overlap area | Generally not removable | Requires access to the bonding interface during assembly | Depends on surface preparation, curing, and environmental durability; internal bond quality is not easily inspectable |
Which Joining Method Should You Choose?
If you feel that the comparison in the table still does not provide you with a reference, I will provide you with the following formula. Feel free to use it.
- Choose rivets: thin plates, no disassembly required, avoid welding heat input or only accessible from one side.
- Choose screws: parts need to be regularly disassembled and assembled, and the base material can provide reliable threads.
- Choose bolts: require higher and controllable clamping force, load-bearing capacity and future maintenance.
- Choose welding: materials have good weldability and require continuous, high-rigidity or sealed joints.
- Choose structural adhesive: connect dissimilar materials and distribute stress
Conclusion
It can be said that by 2026, rivets will still be the most reliable and ideal fasteners available today. Especially with the rapid development of the automation industry, AI applications, and the robotics industry, the usage trend of rivets will be even higher. Therefore, for you, choosing the right type of rivets, materials, and so on will be especially important. This will affect the quality and durability of your products.
DSR Company, as an experienced manufacturer, is able to provide high-quality custom rivet machining services to a wide range of customers. We can provide excellent precision CNC machining services, supporting rapid prototyping and mass production. We will combine your drawings and application requirements to evaluate process feasibility and quotations, relying on advanced production technology to manufacture high-quality rivet parts for you.
FAQ
Q1: Are rivets stronger than screws?
A: Rivets typically offer greater shear strength and vibration-fatigue resistance than screws.
Q2: What is riveting?
A: Riveting is a mechanical fastening process. It securely joins two or more parts together through permanent plastic deformation.
Q3: What type of rivets are strongest?
A: Solid rivet.
Q4: What rivets will not rust?
A: Stainless steel rivet.
Q5: Can rivets be removed and reused?
A: Rivets are essentially one-time fasteners and cannot be reused in most cases.
Q6: What are the different types of rivets used in construction?
A: Solid rivet, blind rivet, structural blind rivet, tubular rivet and split rivet.
Q7: What tools do I need to install blind rivets properly?
A: Rivet gun, power drill, caliper and deburring tool.
Q8: What is the best way to remove rivets?
A: The most commonly used and recommended method for removing rivets is drilling. Of course, you can also use a dedicated rivet removal drill bit.
Q9: What is the best rivet nut for plastic?
A: large-flange/large-head blind rivet.
