Measure
Calipers, rulers, squares, tape measures, scribers and marking tools so students can work to repeatable dimensions.
AccuracyCAD to part
Mission 03 · Prepare to BUILD
Project Forge
Mechanical tools, fabrication equipment and robot build materials
Project Forge gives ReBourne students the tools and raw materials to turn CAD, prototypes and design ideas into real robot parts. This mission funds the measuring, drilling, riveting, cutting, clamping, finishing and stock material needed for the BUILD team to manufacture at FRC scale.
Mission range
Tools, materials and fabrication readiness for the BUILD team
£4k–£9k
03Launch mission
BUILDPrimary subteam
50–70kgRobot scale
£4k–£9kMission range
Mission aim
Turn ideas into working mechanisms.
For people new to FRC: students do not just assemble a toy robot. They build a large, powerful competition machine using metal, plastics, fasteners, bearings, wheels, motors, tools, drawings, jigs, prototypes and repeated testing.
What this mission achieves
Project Forge creates the practical engineering capability behind the robot. It lets students measure accurately, fabricate safely, assemble professionally and iterate quickly when mechanisms fail, bend, slip, jam or need improving.
Equips the BUILD team with core hand tools, power tools and precision measuring kit.
Creates a stock of aluminium, polycarbonate, plywood and prototyping material for mechanisms and test rigs.
Funds fasteners, rivets, spacers, brackets and consumables used throughout build season.
Supports safer fabrication through proper clamping, deburring, finishing and tool organisation.
Project
Forge
Sponsor Logo space reserved here
Forge
Sponsor Logo space reserved here
Sponsor badge / logo
Forge zones
The BUILD team’s engineering stack.
Project Forge can be supported as a full mission or through focused bundles: precision tools, assembly tools, fabrication consumables, raw materials and fastener systems.
Fabricate
Drills, rivet tools, bits, clamps, vices, deburring tools and cutting/finishing consumables for safe workshop and pit build work.
CutDrillRivet
Assemble
Imperial and metric hex tools, sockets, spanners, torque tools, rivets, bolts, nuts, washers, spacers and brackets.
FRC hardwareRepairable
Prototype
Plywood, MDF, cardboard, foamboard, 3D printing filament and quick-build materials for testing ideas before metal parts are made.
Fast iterationLow cost
Manufacture
Aluminium box section, angle, flat bar, polycarbonate and sheet materials for robot structures, guards, brackets and mechanisms.
Robot partsMaterials
Maintain
Files, lubricants, threadlocker, spare blades, drill bits and replacement consumables to keep the robot serviceable through build and competition.
ReliabilityPit ready
What this funds
Tools and materials students can use.
These are example or comparable UK items, not locked purchasing choices. Sponsors can fund the cost, donate equivalent new/quality used tools, or provide materials directly through their own supply chain.
| Item / bundle | Why it matters | Estimated cost | Support type | Example UK link |
|---|---|---|---|---|
| Cordless drill / driver kits x2 | Core build-season tool for drilling, pilot holes, assembly and pit repairs. Prefer one battery ecosystem with spare batteries. | £300–£500 | Financial or in-kind | Screwfix cordless drills |
| Impact driver x1–2 | Fast assembly and disassembly of robot structure. Needs student training to avoid over-tightening. | £150–£300 | Financial or in-kind | Screwfix impact drivers |
| Metric and imperial hex key sets | FRC uses imperial hardware heavily, while UK school equipment often uses metric. The team needs both. | £80–£200 | Financial or in-kind | Metric/imperial hex set |
| T-handle hex drivers | Faster, more ergonomic tools for students repeatedly building and servicing mechanisms. | £100–£250 | Financial or in-kind | Screwfix hex key range |
| Digital calipers x2–3 | Essential for checking shaft sizes, hole spacing, bearing fits, printed parts and manufactured components. | £60–£180 | Financial or in-kind | Machine Mart calipers |
| Squares, rulers and marking tools | Supports accurate layout, repeatable drilling and quality control when students make parts. | £100–£250 | Financial or in-kind | Engineer’s squares |
| Rivet tools and rivets | Rivets are common in FRC structure and mechanism construction. Includes hand riveter, spare mandrels and rivet stock. | £150–£400 | Financial or in-kind | Screwfix riveters |
| Drill bits, step bits, countersinks and reamers | Accurate holes matter for bearings, brackets and structural alignment. Bits are consumables in build season. | £250–£600 | Financial or in-kind | Screwfix drill bits |
| Clamps, bench vice and soft jaws | Safe drilling and cutting depends on proper workholding. This is a major student safety and quality item. | £200–£500 | Financial or in-kind | Screwfix clamps |
| Deburring tools, files and finishing kit | Every cut metal or plastic part should be made safe. Deburring is both an engineering quality and safety habit. | £120–£300 | Financial or in-kind | Deburring tool example |
| Aluminium box section, angle and flat bar | Primary robot structure and mechanism stock for chassis additions, arms, brackets, prototypes and repairs. | £1,000–£2,000 | Financial or material donation | ParkerSteel 2×1 aluminium |
| Polycarbonate sheet | Useful for guards, electronics covers, flexible plates, panels, prototype mechanisms and safe transparent shielding. | £300–£800 | Financial or material donation | Screwfix polycarbonate sheets |
| Plywood, MDF and prototyping board | Low-cost mock-ups, temporary game elements, mechanism tests, jigs and templates before making final metal parts. | £200–£500 | Financial or material donation | B&Q sheet materials |
| Fasteners: 10-32, 1/4-20, 8-32 plus metric M3–M6 | Standardised robot hardware for structures, mechanisms, electrical boards, brackets and repairs. | £500–£1,000 | Financial or in-kind | Accu fasteners |
| 3D printing filament and heat-set inserts | Supports prototypes, sensor mounts, cable guides, covers, spacers and non-critical robot parts. | £300–£700 | Financial or material donation | Technology Outlet filament |
| Consumables and maintenance stock | Threadlocker, lubricants, blades, sandpaper, cutting fluid, wipes, masking tape and replacement tool consumables. | £300–£700 | Financial or in-kind | Screwfix consumables |
Mission budget
Mission range: £4k–£9k.
Project Forge can begin with a core set of fabrication tools and build materials, then grow into a stronger mechanical setup with more stock, spares, consumables and workshop-ready equipment. Sponsors can fund the whole mission, co-sponsor a focused part of it, or donate tools, materials or fabrication expertise in kind.
| Budget line | Estimate | Notes |
|---|---|---|
| Core fabrication setup | from £4k | Provides the essential measuring tools, assembly tools, drill/rivet equipment, basic materials and consumables needed to begin building at FRC scale. |
| Enhanced BUILD setup | up to £9k | Creates a stronger mechanical base with broader tooling, more material stock, better workholding, fastener systems and replacement consumables. |
| Core hand tools and measuring tools | £900–£1,500 | Hex tools, sockets, spanners, calipers, squares, rulers, marking tools and files. |
| Power tools, drill/rivet equipment and workholding | £1,700–£2,900 | Drills, impact driver, drill bits, step bits, rivet tools, clamps, vice, soft jaws, deburring and finishing tools. |
| Robot build materials | £1,800–£3,000 | Aluminium tube, sheet aluminium, polycarbonate, plywood, MDF, prototype materials and 3D printing stock. |
| Fasteners, consumables and replacements | £1,600–£2,600 | Imperial and metric bolts, nuts, washers, rivets, spacers, threadlocker, cutting fluid, blades and general build-season replacements. |
| Indicative mission range | £4k–£9k | A practical sponsorship range for the mechanical build and fabrication mission. |
£250+
Supports drill bits, rivets, files, clamps, stock materials or build consumables.
£1,000+
Funds a visible bundle such as measuring kit, hand tools, fasteners or aluminium stock.
£4k–£9k
Funds the full Project Forge mission as the named lead sponsor.
Student impact
What this unlocks for students.
Project Forge is where students become makers, not observers. They experience the engineering loop: design, make, test, fail, improve and compete.
Mechanical confidence
Students learn to use real tools safely, choose materials, read dimensions, make parts and understand why accuracy matters.
Design judgement
The BUILD team can compare prototypes, understand trade-offs, improve mechanisms and see how CAD becomes physical hardware.
Competition resilience
With tools, spares and materials available, students can repair and adapt the robot rather than watching a season end with one broken part.
Forge pathway
From stock to robot.
A practical route from donated tools and materials to student-made robot systems.
Tool base
Secure the core measurement, assembly, drilling, riveting and finishing equipment.
Material stock
Build a labelled supply of aluminium, polycarbonate, prototype board, fasteners and consumables.
Training
Train students in measuring, marking, safe drilling, deburring, clamping, assembly and quality checks.
Build season
Use Project Forge to prototype, manufacture, repair and improve the robot throughout the FRC season.
Sponsor this mission
Be the forge partner.
Project Forge sponsors help give students the hands-on engineering capability to manufacture, assemble and maintain a large-scale competition robot.
Recognition as a Project Forge lead sponsor, co-sponsor or in-kind supporter.
Logo space on this mission page and the ReBourne partner page.
Recognition on the pit sponsor board and build-season updates.
Opportunity to donate tools, materials, machining support or fabrication expertise.
Visible association with practical engineering skills for girls in FRC.
Mission
03 Copper · Bronze · Steel
03 Copper · Bronze · Steel
Reserved for sponsor