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Should You Switch from Pop Rivets to Semi-Tubular or Solid Rivets?

In manufacturing, the choice of fasteners plays a crucial role in product quality, cost efficiency, and assembly processes. While pop rivets are commonly used for their ease of installation, switching to semi-tubular or solid rivets can offer notable benefits for certain applications.

The Difference Between Pop Rivets and Semi-Tubular or Solid Rivets

Pop rivets, also known as blind rivets, are ideal when access is limited to only one side of the materials being joined. They are favored for quick installations in less demanding applications. Conversely, semi-tubular and solid rivets require access from both sides but provide a more robust and durable joint. These are preferred in situations where greater strength and longevity are crucial.

Why Switch to Semi-Tubular or Solid Rivets

Switching from pop rivets to semi-tubular or solid rivets can bring several advantages:

Cost Efficiency Through Enhanced Rivet Selection

A manufacturer specializing in backup alarms was using pop rivets out of habit and a lack of knowledge of other options. With annual volumes of 700,000 parts, they were spending a significant amount on purchasing pop rivets. Upon discovering that semi-tubular rivets were more cost-effective and offered better quality, they decided to switch. This change, while requiring an upfront investment in new impact riveting equipment, was justified by the substantial savings on the cost of rivets, ultimately reducing overall production expenses.

Design Optimization and Functional Improvements

In the RV industry, one manufacturer aiming to bring production back to the U.S. and streamline their assembly process turned to Orbitform for assistance. Their existing product design and the use of pop rivets were causing functional issues; specifically, the joints were not moving freely due to the side load forces exerted during assembly. After a thorough consultation with our team, they opted to switch to a more suitable type of rivet and implemented a redesign of the component. These adjustments, combined with the elimination of the need for large inventories due to reshoring, led to significant improvements. The manufacturer achieved a complete return on their investment in new production equipment within just one year, enhancing both product functionality and operational efficiency.


The decision to switch from pop rivets to semi-tubular or solid rivets can dramatically impact the manufacturing process, product quality, and cost efficiency. As demonstrated by the examples above, understanding the specific needs of your application and exploring alternative fastening solutions can lead to significant improvements and savings. Contact us today to reassess your fastening needs to stay competitive and innovative in the fast-paced world of manufacturing.

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