Mechanical Fasteners vs. Adhesive Tapes: Pros and Cons of Each

Have you ever thought, “Gee, I wonder if I should use nails or adhesive tape to mount this picture on the wall?” 

Or maybe not, unless you’ve got a strict landlord to worry about. But although choosing a bonding method might seem like a minor detail when you’re doing work around the house, you’ll want to consider all your options when it comes to large-scale manufacturing projects. 

Strouse works more closely with adhesive tape as a flexible material converting company than mechanical fasteners. However, we're committed to providing unbiased information as you educate yourself on potential bonding solutions to fit your needs.

As you learn more, you'll understand your different options and which factors to consider when selecting a joining method for your project.

What Are Mechanical Fasteners?

Mechanical fasteners are typically metal components that bind one surface to another. Examples of mechanical fasteners include rivets, screws, brackets, pins, and retaining rings, commonly seen in joining or mounting applications. 

HOW ARE FASTENERS USED TO JOIN OBJECTS?

Fasteners can be temporary, semi-permanent, or permanent, depending on the purpose of the application. 

Permanent fasteners, such as rivets, are installed by placing the rivet in a hole and applying pressure to the other side to deform and lodge it in place.

Semi-permanent fasteners, like bolts, are combined with nuts and washers to create a tight, potentially removable bond between two surfaces. 

Temporary fasteners, like screws, can be paired with brackets to support heavier applications, such as shelves, but removed later. However, using mechanical fasteners in applications like mounting will still result in surface damage to the wall.

As we discuss the pros and cons of using fasteners, consider whether your application needs a temporary solution or a longer-lasting alternative. 

What Are the Pros and Cons of Using Mechanical Fasteners?

Mechanical fasteners are powerful joining solutions but can be heavy and bulky, meaning they might not fit your application.

PROS OF MECHANICAL FASTENERS

• • Mechanical fasteners wedge into surfaces, providing high strength and making them unlikely to fall off naturally.
  • Their robust design ensures long-lasting performance.

• • Mechanical fasteners can resist movement better than adhesives, which might shift under significant force.
  • Although fasteners are strong, they may loosen over time.

• • Some mechanical fasteners are easy to disassemble, which is crucial for applications requiring routine maintenance.
  • Similarly, depending on the adhesive type, adhesive tapes can be designed for easy removal, medium-duty use, or permanent fixtures.

• • Mechanical fasteners provide full-strength joints immediately upon application, often resulting in a quick and efficient process, depending on the fastener type and its application.

CONS OF MECHANICAL FASTENERS

• • Most mechanical fasteners need holes to work, and some, like sharp-tipped screws, create their own.
  • This puncturing can damage the surface, compromising its aesthetic and structural integrity.
  • Additionally, lining up and punching holes for fasteners is more time-consuming than applying double-sided adhesive tape. 

• • The added weight comes from the fastener and the entire mounting fixture.
  • Screws securing larger metal brackets can weigh down the fixture and warp the holes, leading to misshapen fixtures over time.

• • Changes in the shape of the holes can allow moisture to enter, increasing the risk of rust and other forms of corrosion.
  • Bi-metal corrosion between different metals can also occur over time.

• • Mechanical fasteners establish fixed points of tension, making surfaces more vulnerable to breakage.
  • Due to this risk, many opt for adhesive tape as an alternative.

What Are Adhesive Tapes?

Adhesive tapes are flexible materials that use bonding substrates to join objects and surfaces. 

While you're probably picturing everyday masking or duct tape in your head, the adhesive tapes we're discussing are heavy-duty double-sided tapes that can endure similar amounts of tension. 

HOW ARE ADHESIVE TAPES USED TO JOIN OBJECTS?

Adhesive tapes can combine objects and materials of different sizes and shapes, both flexible and solid.

While you may have used adhesive tape to mount paintings or dry-erase boards, many people aren't aware that flexible tapes can bond together trailer walls, attach fixtures to ceilings, or hold a functioning scooter intact using their considerable strength. 

What Are the Pros and Cons of Using Adhesive Tapes?

Adhesive tapes can be strong, custom-made alternatives for bonding, but they also risk higher costs, expiration dates, and slippage due to environmental factors. 

PROS OF ADHESIVE TAPES

• Double-sided options available with different substrates on each side for optimal adhesion.
• Can be laminated by converters to meet specific surface requirements.

• Unlike mechanical fasteners, adhesive tapes offer a smooth surface, avoiding geometric or aesthetic issues.
• Thin adhesive tapes can provide strong bonding even with a powerful adhesive.

• Adhesive tape can serve multiple purposes, such as sealing, shock absorption, and sound dampening.
• Materials like foam are flexible, expanding or contracting with temperature changes.

• Adhesive tape is a lightweight alternative to mechanical fasteners, reducing the overall weight of devices or surfaces while maintaining strength.
  
  

CONS OF ADHESIVE TAPES

• • Adhesive tapes can struggle on certain surfaces without prior treatment.
  • Converters may use corona treatments to temporarily improve adhesion on low surface energy (LSE) plastics.
  • Proper surface preparation during application is crucial for forming a strong bond; failure may lead to bond failure.

• • Environmental conditions can influence the effectiveness of adhesive tape.
  • Depending on the tape's composition, moist or humid environments can affect the adhesive properties.

• • Adhesive tape has a shelf life, similar to a best-by-date for food.
  • Manufacturers mark rolls with a recommended use-by date, though many adhesives remain effective well past this date.

• • Standard adhesive tape is generally affordable, but costs can rise with custom design jobs.
  • Automation can reduce labor costs, making customization more cost-effective.

Which Bonding Method Should I Choose?

Before you decide between mechanical and adhesive bonds, you must understand that there are more than two bonding options. There are plenty of other alternatives, each with its pros and cons. 

For instance, liquid adhesives are messy and challenging to work with unless your operators are fully trained. Welding can be powerful, but it can also cause damage to your respective surfaces. 

The method you choose will ultimately depend on your specific application and needs. 

A mechanical fastener might be your best choice for an application that requires maintenance or must withstand movement. However, powerful but lightweight bonding applications like fixing signs, logos, windows, or large panels are often perfect opportunities for custom tape applications. 

If you’re looking for increased project consistency, reliability, and ease of application, consider using adhesive tape as your solution. Many double-sided tapes are adept at bonding both similar and dissimilar materials. With the help of an adhesive tape converter, you can figure out which material might best suit your product and application process. 

To get started, consider reaching out to Schedule a Project Consultation, where our experts will help you plan and prototype materials to test in your process, allowing you to see how the flexible materials perform.

Still hesitating? Our Learning Center has additional information about different bonding methods that will help you make a choice. 

Originally published: March 14, 2023