Rivet vs Bolt: MIL-STD-1759 Aerospace Selection Guide

Published: 2026-10-13

In aerospace and sheet metal structures, rivets and bolts each have their place. MIL-STD-1759 (Rivets and Rivet-Type Fasteners Preferred for Design) provides a systematic selection framework.

Solid Rivets: The Cheapest Permanent Joint

Solid rivets require access from both sides: shop head on one side, bucked on the other. Advantages:

  • High shear strength (comparable to same-diameter bolts)
  • Lowest cost (material + labor)
  • Lightweight (no threads or nut weight)
  • Good sealing when properly driven

Disadvantage: requires two-side access and is permanent. Used for non-serviceable structural joints.

Blind Rivets: One-Side Access at a Cost

Blind (pop) rivets are installed from one side; the mandrel pulls and breaks, expanding the rivet body. Required for closed sections (tubes, fuel tanks).

But MIL-STD-1759 notes the limitations:

  • 20–30% lower shear strength than equivalent solid rivets
  • Mandrel retention can cause FOD (foreign object damage)
  • Worse fatigue performance
  • 3–5x more expensive

Bolts: Removable High-Reliability Joints

Bolts and nuts are used where:

  • Disassembly for maintenance is needed
  • High or cyclic loads are present
  • Precise clamp-up control is required
  • High inspection quality is needed

Decision Tree

1. Need disassembly? → Bolt

2. Can't access both sides? → Blind rivet

3. Permanent + two-side accessible + moderate load? → Solid rivet

4. Cyclic load or safety-critical? → Bolt + locking feature

Toprecision provides rivet and bolt selection guidance for sheet metal and light-alloy structures.