Boxtube construction

Tube-based construction uses square (or rectangular) extrusion as the main structure. It’s popular for building strong, minimal-friction drivetrains, arms, and linear slide supports. Teams often use aluminum tubing or extruded building systems like REV or GoBILDA.

How It Works

• Structural members are made from 1x1" aluminum tube or extrusion.

• Plates, brackets, or gussets are bolted to the tube faces.

• Components like slides or bearings ride along or inside the tubing.

Pros

• Very Rigid: Tubing resists bending, great for arms and frames.

• Modular Mounting: You can tap into tube faces or use brackets.

• Efficient Use of Space: Great strength-to-volume ratio.

Cons

• Requires Precision: Drilling/tapping holes straight is critical.

• Difficult to Modify: Custom tube setups don’t allow sliding or quick realignment.

• Access Needed: Tube interiors are hard to reach once closed off.

FTC Tips

• Use 1x1” 1/16” wall aluminum tubing (e.g., 6061-T6) for strong but light framing.

• Tap ends for M3 or M4 screws using 3D-printed guides or jigs.

• Clamp or bolt corner gussets for rigid 90° joints.

• Consider nested ¾” tube inside 1” for telescoping mechanisms.