When a manufacturer of industrial sanding products noticed quality issues in their sandpaper assembly process, they didn’t settle for "good enough." Their engineering team recognized the risk of inconsistent fastening with staples and set out to find a better way—one that would improve product integrity without slowing down production or adding unnecessary steps.

This wasn’t just a search for a new machine—it was a search for a smarter process.

The Problem: Staples Weren’t Getting the Job Done

The team was using staples to fasten multiple layers of abrasive material, but the results were hit or miss. The staples often failed to pierce every layer or hold the layers securely, which created weak points and quality concerns in the final product.

They knew the assembly process had to change, but they also did not want to add any steps for drilling or cutting holes into the material. They needed a solution that could pierce and fasten all in one motion while still supporting automation and speed on the production line.

The Solution: Testing a New Process in the Lab

That’s when they partnered with Orbitform. Our engineering team evaluated the application in our Solutions Lab, where we replicate real-world production scenarios to test and validate new processes. Based on their needs, we proposed using split rivets paired with an impact riveter as a promising alternative. Split rivets are designed to pierce through layers of material and form strong mechanical connections without requiring pre-drilled holes.

To solve the challenge of rivet orientation during feeding, Orbitform’s engineers developed custom lower tooling with multiple divots in the anvil. This feature allowed the rivet legs to curl properly every time, improving consistency without slowing down production.

Proving It Out with Real Samples

Our team ran sample parts through the new setup in our lab, using an impact riveter with automatic rivet feeding to demonstrate how this solution could streamline production while boosting assembly quality. The finished samples were provided to the customer for evaluation of joint strength, shear load capacity, and overall performance.

By taking initiative, the customer was able to evaluate a better, more reliable assembly process without disruption to current operations.

Engineering Smarter Assembly from the Ground Up

By taking the time to evaluate their current process and test an alternative, the customer’s engineering team demonstrated what thoughtful, problem-solving design can accomplish. They didn’t just settle for a workaround—they looked for a solution that would improve product quality, reduce risk, and support automation down the road.

It’s a reminder that even small changes in tooling and process design can have a big impact on long-term performance and reliability. When quality matters and production demands are high, rethinking how parts come together can lead to stronger products and stronger confidence in the assembly line.

Looking to improve your fastening process?

At Orbitform, we partner with manufacturers every day to test, validate, and engineer assembly solutions that work. Bring us your toughest challenge. Our Solutions Lab is ready to help you explore alternatives and prove out what’s possible—before you make the investment.