6 Types of Rivets, Uses, and Alternatives for Joining Metal

rivets vs hardware insertion

Table of Contents

Rivets are one of the oldest and most reliable methods for fastening materials. From Egyptian spearheads to bronze age axes, and right through to current manufacturing methods, the rivet has some serious staying power. Whether you’re working with solid or sheet materials, understanding the types of rivets is key to selecting the right one for your project

At SendCutSend we offer hardware insertion services for a wide variety of materials and thicknesses to fit just about any application. Is a rivet right for your project, or is there a better alternative? What material considerations are there? Does this project call for a solid rivet, a pop rivet or a rivet nut? Answers to these questions and more can be found below, so dig in!

6 Types of Rivets and Their Best Uses

Rivets are typically composed of a head and a shaft which is slightly longer than the thickness of the two pieces it will fasten. The shaft end of the “solid” rivet is inserted through pre-drilled holes, then deformed creating a second head which permanently secures the two pieces. Rivet type fasteners are excellent in shear loading, have good tensile strength properties, and are nearly immune to vibration loosening.

We’ve compiled a short list of the most popular varieties to get you on your way to successful joinery.

1. Solid Rivet

This is the great-granddaddy of all other rivets, consisting of a simple shank or shaft with a head at one end.

Structure: One-piece shaft with a head.

Head Profiles: Pan, domed, mushroom, flat.

Pros: Extremely durable, consistent across batches, ideal for permanent joins.

2. Blind Rivet

Commonly known as the “pop” rivet, blind rivets are especially useful when only one side of the assembly is accessible.

Use case: Accessible from only one side.

Installation: Insert the mandrel and pull to expand the rivet body.

Variants: Suited for metal, fiberglass, plastics, and wood.

3. Split (Bifurcated) Rivet

Split or bifurcated rivets are similar in shape to solid rivets except that the tail end of the shaft is split, allowing a special wedge tool to be used to expand the two “legs” once the rivet is inserted through the two pieces of material.

Structure: Shaft splits into legs at the tail end.

Installation: Legs flare out using a wedge tool—requires access to both sides.

Ideal for: Soft plastics, leather, fabric.

4. Tubular Rivet

Tubular (or semi-tubular) rivets resemble a solid rivet with a hole drilled partway through the tail end of the shaft.

Feature: Partially hollow shaft.

Benefit: Requires about 25% less force to set; ideal for pivot points. SendCutSend

5. Flush Rivet

These rivets can be blind or solid, and have obvious advantages for aesthetics and aerodynamic drag characteristics (think, less turbulence on the airplane wings). 

Design: Countersunk head aligned with surface for a smooth finish.

Benefit: Aesthetic and aerodynamic—common in aviation and sleek designs.

6. Metal Rivet Materials

Each of the rivets mentioned can be produced from various metal alloys. One of the only limitations to what material a rivet can be made of is that the shaft must be ductile enough to deform without cracking.

Common alloys: Aluminum, low-carbon & high-carbon steel, stainless steel, brass, copper.

Guidelines: Shaft material must be ductile enough to deform without cracking. Harder rivets (e.g., high-carbon steel) may require heat during installation.

What are Alternatives to Rivets?

Rivets are cost‑effective and dependable, but they have downsides: permanent installation, added weight, and can be labor-intensive. Alternatives include PEM hardware and self-clinching fasteners.

Press Fit Nuts

In the DIY world, by far the most popular type of rivet is the pop rivet, mainly because it can be used when you only have access to one side of your work. The biggest downside? Unless you feel like taking a drill to your shiny new project, that rivet is permanent. 

Rather than specifying rivet holes in your next part, once it’s uploaded to our app select “Hardware Insertion.”

Hardware Insertion

Fig. 1: Adding a press fit nut to any hole in your part is simple. 

Then click “Open Catalog” and you’ll see all the available hardware options. We’ve made the process simple, so don’t worry if your specified hole is not quite the right size for your fastener–we’ll automatically resize the holes to match the hardware exactly. 

Hardware Insertion

Fig. 2: The 3D preview allows you to visualize the fastener and check installation direction.

Our press fit nuts are vibration resistant and won’t break loose like often happens with tack welded nuts. They can also be installed in metal sheets as thin as 0.048”.

Self-Clinching Studs

You can think of self-clinching studs as the yin to a press fit nut’s yang: like a nut, a self-clinching stud requires access to only one side of the assembly. An added benefit over a standard nut and bolt assembly is that a stud is fixed so that it cannot rotate as you lie on your back trying to thread on a nut with no visibility. Oh, that’s never happened to you? Lucky you…

Standoffs

PEM standoffs installed by SendCutSend add the ability to space two workpieces a fixed distance from one another, which is something a rivet really can’t do well. Standoffs are often used to space a printed circuit board off of the base plate, but can be used to allow airflow between two parts, or many other applications.

Another benefit of SendCutSend inserted hardware, along with our tapping service, is that they are always installed square (or perpendicular to the mounting surface). This is particularly difficult to accomplish in the home shop without specialized equipment. For an in-depth look at each type of fastener and how best to use it, take a look at our article on Designing with Sheet Metal.

Limitations of Using Rivets vs. PEM Fasteners

Time

In most cases, rivets require a pre-drilled set of holes that line up perfectly in the workpieces. Although this isn’t a problem when you make your parts with our precision lasers, it also involves selecting the correct rivets and in many cases, purchasing specialized equipment to install them. 

Labor

When specifying PEM fasteners in your sheet metal from us, the amount of work per fastener is reduced to the time it takes to thread a nut or bolt.

Consistency

If you’ve ever worked with pop rivets, you know that whether it’s user error, component variability, or misalignment, there can be significant variability in the quality rivet-to-rivet.

✅ Comparing Rivets vs Fasteners: Pros & Cons

FeatureRivetsPEM Hardware
Installation TimeRequires drilling, alignment, toolsFaster; part is pre-inserted
PermanencePermanentRemovable and replaceable
ConsistencyUser-dependent variabilityFactory precision, uniform installation
Vibration ResistanceVery highHigh

Typical Applications of Rivets and Fasteners

Aerospace and sheet metal: Rivets resist vibration loosening.

RV manufacturing: Ideal for joining aluminum, plastic, and plywood.

Marine uses: Waterproof and ideal for shipbuilding.
PEM alternatives work where removability and threaded interfaces are desired

Although limitations to rivets exist, there are still many great applications across various industries: aircraft construction and sheet metal fabricators still often employ riveted joints because they are nearly immune to loosening with vibration. The RV industry uses riveting techniques to fasten materials like plastic, plywood and aluminum together–try doing that with a welded joint sometime. Further, if the proper precautions are taken, rivets can be waterproof making them the fastener of choice in many shipbuilding applications. 

For a deeper dive into each of our PEM fasteners, and additional insight into how you can use them in your next build, take a look at the Hardware Guidelines, and Best Practices writeups. 

Material Selection for Hardware Installation

When selecting fasteners, consider material type, sheet thickness, hole size, and finish orientation. For instance, using 5052‑H32 aluminum sheet? Choose compatible PEM nuts or standoffs from our Hardware Catalog, including min/max sheet thickness guidelines.

Solve Your Design Problems with SendCutSend’s Hardware Installation Service

Although rivets definitely have seniority in the wide world of fasteners, our hardware selection, which includes nuts, studs and standoffs offers a wider range of potential applications. Not only that, but because they employ a threaded joint, PEM hardware is completely removable if your application doesn’t call for a permanent joint. Installed fasteners, like rivets, are also extremely vibration resistant, which allows them to be used in automotive and other repetitive motion applications.  

So how do you determine what fastening method is best? The answer to that depends on the application; materials, end use, environmental factors and even available equipment. What we can offer is a wide range of quality hardware pre-installed to save you time, and since they start at under $1 per fastener, a little money too!

FAQs Around Rivets

Do I need a rivet or a rivet nut?

Do you want the assembly to be able to be taken apart for storage or moving? Better use hardware insertion. Are you looking for the absolute lightest weight and best vibration resistance? Go with a solid shaft rivet. 

What is the difference between a blind rivet and a pop rivet?

Actually, nothing! The original blind rivet was developed in Britain in 1916. During and just after WWII the POP ™ rivet  exploded in popularity due to its comparative ease of use. It’s still the most popular type of rivet today, with the trademark now owned by the Stanley corporation. 

Why not just weld it? 

While a tack weld can’t be beat for fastener weight or speed, rivets (and the rivet nut hardware we offer) have much better vibration resistance and repeatability. Plus, try welding a wood panel to an aluminum sheet sometime.

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