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The 8 decisive criteria for selecting the optimum blind rivet nut

Published on 28.08.2025

Blind rivet nuts are indispensable fasteners in industrial manufacturing and trade. They enable load-bearing threads to be created in thin components or components that are only accessible from one side – for example in the automotive, electrical, solar and white goods industries. Inserting blind rivet nuts is a quick and efficient process that can be carried out without in-depth specialist knowledge, such as that required for welding. However, not every blind rivet nut is suitable for every application. If you want to achieve a reliable, long-lasting connection, you need to consider various technical aspects. Below you will find the eight most important selection criteria, supplemented by industry-specific examples and practical explanations.

1. Suitable thread size: 
Focus on load capacity and installation situation

The thread size (available from GESIPA® as standard from M4 to M10) determines which screws can be used with the blind rivet nut. Particularly common sizes such as M5, M6, M8 and M10 are found in numerous applications – from fastening dashboards and safety-related components in vehicles to mounting solar panels. The selection of the correct thread size depends on the expected load, the grip range and the available space. The ‘M’ in the thread size designation stands for ‘metric’, the number following it for the nominal diameter of the thread in millimetres. Other dimensions and special designs, such as imperial thread dimensions, are available on request.

2. Shank shape and anti-rotation: 
Optimally adapted to the component

The shank shape has a significant influence on the anti-rotation of the blind rivet nut. The following shank shapes are available as standard from GESIPA®:

Round shank

Blind rivet nuts with a smooth round shank are universally applicable, especially at low torques. This gives them a wide range of applications and also has the advantage that they fit into a simple drill hole that does not require special tools.

Splined shank

These are also round shank rivet nuts, but with a splined shank design. The splines anchor better in the material than a smooth shank and thus distribute the forces better. This is particularly advantageous for softer materials such as aluminium profiles in solar technology or for light housing fastenings. The round shank and splined shank shapes are particularly suitable for mobile and industrial applications and are also ideal for reworking and repairing screw connections.

Partial square/partial hexagon

These blind rivet nuts have a partially round and partially square or hexagonally flattened shaft. The shaft shapes offer a combination of easy installation and increased resistance to rotation, but require a special hole profile. This shaft shape is particularly suitable for industrial applications where the pilot hole is made by a machine process.

The more complex the rivet nut body shape, the more complex the hole preparation – this should be taken into account during planning. In addition to the rivet nut body shapes, some GESIPA® blind rivet nuts offer additional features that combine the advantages of round rivet nut bodies and partial square/partial hexagon rivet nut bodies, offering an efficient manufacturing process with high resistance to rotation.

 

3. Rivet nut body length: Perfect adaptation to the grip range

The correct rivet nut body length is crucial for a secure fastening. The rivet nut body length depends, among other things, on the grip range/area of application of the blind rivet nut, which is determined by the thickness of the components into which the blind rivet nut is to be inserted.

If the rivet nut body/clamping range is too short, the nut will not hold reliably because no closing head can form; if it is too long, material deformation or loose connections may occur. GESIPA® specifies a setting range for each blind rivet nut, which must be matched to the actual material thickness. GESIPA® multigrip blind rivet nuts are ideal for applications with widely varying grip ranges or for versatile use.

In series production, for example with varying sheet thicknesses in the white goods industry, a universal solution or a custom-made product may be advisable. GESIPA® also develops and produces custom-made blind rivet nuts in close cooperation with you. Please contact us for applications with special requirements for fasteners.

Further information   contact

4. Material selection: 
Corrosion protection and strength for every environment

Choosing the right material for blind rivet nuts is crucial for the reliability, durability and safety of the connection. In addition to pure technical feasibility, costs, environmental conditions and mechanical loads play a key role. GESIPA® offers blind rivet nuts in various materials with properties that are specifically suited to certain areas of application:

Aluminium

Very low weight and good corrosion resistance and seawater resistance. Easy to process, but has lower strength than steel or stainless steel blind rivet nuts, which also means that the tightening torque is lower. Commonly used in lightweight constructions in mechanical engineering or in the field of e-mobility. It is particularly suitable for applications where weight needs to be saved and the component is not exposed to high forces.

Steel (galvanised)

Robust and economical solution for standard applications. Blind rivet nuts made of galvanised steel have high mechanical strength, but should not be used in damp or salty environments with the standard zinc coating, as the corrosion resistance in these environments is not strong enough. For applications in critical environments, e.g. outdoors or in contact with moisture, additional surface coatings such as zinc-nickel surfaces are available on request. They are used, for example, in fitness equipment, inside machine frames or in metalworking in workshops. Blind rivet nuts made of steel offer the universal standard solution for creating load-bearing threads in various applications.

Stainless steel (A2/A4)

Very good resistance to corrosion, chemicals, high temperatures and salty air. Stainless steel blind rivet nuts also have a high mechanical load capacity. These properties are ideal for outdoor use, for example in solar systems, in shipbuilding or in the food industry. If a long-term and rust-free connection is required in the application, stainless steel blind rivet nuts are the right choice.

Monel®

Nickel-copper alloy with excellent corrosion resistance and high resistance to acids, alkalis and seawater. Monel blind rivet nuts also have very high strength, even at high temperatures. From a technical point of view, these are perfect conditions for a blind rivet nut, but Monel® blind rivet nuts are very expensive and should only be used where stainless steel rivet nuts reach their limits. They are often used in environments where extreme conditions prevail, for example in chemical plants or in the energy sector.

Blind rivet nuts are listed in the GESIPA® catalogue in the following colours for material identification, depending on the material:
Aluminium = grey, steel = dark blue, stainless steel A2 = light blue, stainless steel A4 = green, Monel® = dark red

 

The choice of material should always be based on the environmental conditions and the requirements for the connection.

If you are unsure, GESIPA® offers technical advice and product selection support – even for custom-made products.

Contact us

 

Ask yourself the following questions before deciding on one of the above materials:

  • Will the component be permanently exposed to moisture or chemicals?
  • Will it come into contact with salt water or extreme temperatures?
  • Is weight a decisive factor?
  • Does the connection need to be made from a single material (e.g. aluminium/aluminium or steel/steel)?
  • Does the connection need to function permanently without maintenance – e.g. in applications that are difficult to access or safety-critical?

5. Head shape: contact surface, appearance and function

The choice of head shape has a direct influence on the load distribution, the assembly conditions and the appearance of the connection. GESIPA® offers a range of head shapes to suit different applications:

Dome head

This design offers a large contact surface, which distributes the force well across the material – especially with softer materials (e.g. plastics, aluminium sheets).
Unlike the countersunk head variant, no countersinking is required, which makes assembly faster and preparation of the drill hole easier. Flat head blind rivet nuts are often used in mechanical engineering, vehicle construction and plant engineering.

Countersunk head:

The countersunk head sinks flush into the material when a suitable countersunk hole is provided. This variant is ideal when a flat surface is required – for example, in furniture fittings, panels, or aerodynamically relevant surfaces in vehicle construction. However, countersunk blind rivet nuts require a precisely countersunk hole before setting, which slightly increases the assembly effort compared to dome head blind rivet nuts, for example.

Small head

The small head blind rivet nuts have a reduced head height, which is visually discreet but does not offer complete countersinking. They are ideal for thin-walled or delicate components where little space is available for the contact surface. The small head blind rivet nut offers good load distribution and a discreet appearance – for example, for connections in the electronics sector.

The head shape contributes significantly to the functionality and appearance of the connection, as well as protecting the component. While the dome head scores points for its simple preparation, the countersunk head offers a high-quality appearance with precise machining. The small head is ideal when an efficient manufacturing process, the smallest possible distances between the assembly components and a discreet appearance are required.

6. Open, closed or sealed? 
Blind rivet nuts for every assembly situation

A major advantage of blind rivet nuts is their ability to be set blind – i.e. from one side only. This is ideal for applications in hollow profiles, closed systems or rear walls, such as those found in vehicle construction, air conditioning technology or the assembly of photovoltaic systems. GESIPA® offers a wide range of specialised riveting tools for every application, from battery-powered blind rivet nut tools for maximum freedom of movement to automated riveting solutions for industrial manufacturing. GESIPA® also offers accessories for the riveting tools, such as extended threaded mandrels and nosepieces, providing additional solutions for applications with accessibility problems and thus enabling efficient working.

In addition, the design of the blind rivet nut plays a decisive role in the application. A basic distinction is made between open and closed rivet nuts.

Open blind rivet nuts

This is the standard version of blind rivet nuts, in which the entire rivet nut body is open on the inside. Open blind rivet nuts are suitable for applications where moisture is not a major factor or where there are no special requirements for tightness. Another advantage of using open blind rivet nuts is that the screw length does not have to be universal and does not have to be adapted to the blind rivet nut.

Closed blind rivet nuts

In closed blind rivet nuts, on the other hand, the end of the rivet nut body is closed. This protects the thread from dirt and moisture, which is why closed rivet nuts are often found in outdoor applications or applications where there are sensitive components on the back that must not be damaged by a screw.

GESIPA® product tip:

The G-Sealed® blind rivet nut is a blind rivet nut with a special coating on the underside of the setting head and a closed design which, thanks to an integrated underhead seal, creates an immediately tight connection as soon as it is set – without any additional sealing.
It is ideal for applications where moisture, dust or chemicals must be reliably kept out, such as in automotive engineering, switch cabinet construction or housing construction. The seal is elastic, dry and environmentally friendly – and works equally well on metallic and non-metallic materials.

This makes it the product of choice for anyone who needs a permanently sealed threaded connection.
G-Sealed® blind rivet nut

 

7. Process reliability and traceability: 
meeting quality requirements

In quality-critical industries such as the automotive industry, complete documentation of fasteners is often essential. In this regard, it is not only important to select the right blind rivet nut for an application, but also to choose a setting tool that meets the quality requirements. This is where GESIPA® blind rivet nut tools with integrated setting process monitoring come into play, such as the the FireRex® C WinTech and the FireFox® 2 C WinTech. Both tools evaluate the setting process using integrated position and force sensors. This allows assembly errors to be detected immediately, process windows to be defined and all data to be digitally recorded for quality assurance purposes. A coloured LED and the option of connecting to a PLC control system show the operator in real time whether the rivet connection has been set correctly.

Further information on setting process monitoring and the appropriate blind rivet nut tools equipped with the relevant technology is available here:
FireRex® C WinTech FireFox® 2 C WinTech

8. Compatibility with setting tools: 
efficiency in assembly

In general, any blind rivet nut can be processed with any setting tool, but it is important that the setting tool also meets the relevant requirements for the blind rivet nut. Different types of tools are used depending on the thread size, material and desired process speed. Blind rivet nut tools from GESIPA® are optimally matched to our own blind rivet nuts, which increases tool life and minimises wear:

Manual rivet nut tools

For smaller projects or everyday maintenance work, manual rivet nut tools are the perfect addition to any toolbox.
Manual rivet nut tools

Battery-powered rivet nut tools

Battery operation allows flexible use of blind rivet nut tools, making them ideal for use on construction sites or with angled components. In addition, GESIPA® battery-powered tools are part of the CAS system, in which a wide variety of tools from different manufacturers can be combined with each other thanks to standardised batteries.
Battery-powered rivet nut tools

Pneumatic-hydraulic rivet nut tools

Robust blind rivet nut tools for manual or semi-automated processing in industrial manufacturing. They offer high setting speeds, consistent quality and can be equipped with process monitoring systems such as WinTech if required. They also offer a wide range of applications and can process a wide range of blind rivet nuts.
Pneumatic rivet nut tools

Fully automatic systems

Integrated systems for high-volume production lines where blind rivet nuts are automatically set, monitored and documented. Blind rivet nut systems integrated into robots are ideal for series production with maximum efficiency and 100% traceability.
Rivet automation

FAQ – Frequently asked questions about selecting blind rivet nuts

What hole size is required?

The hole should be at least 0.1 mm larger than the shaft diameter of the blind rivet nut. Hexagon blind rivet nuts require a special hexagon hole for setting the blind rivet nut.

Are blind rivet nuts waterproof?

Blind rivet nuts are not watertight as standard. However, tight connections can be achieved with a closed design and additional sealing (e.g. G-Seal).

Conclusion: The optimal blind rivet nut: 
Key to quality and durability

Choosing the right blind rivet nut has a significant impact on the quality, safety and service life of your connection. Consider all technical parameters and industry-specific requirements to find the optimal solution for your application. If you are unsure, we recommend consulting the GESIPA® technical team to find a customised and cost-effective fastening solution.
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