I have been thinking about the riveting route for stabilizing the tapes on the hoops, and also making channels in the tapes. So tape channels worked good for you, with what type of hooping? Flat steel, spring steel, etc?

They have to be round because the costume designer says she wants them round.

These are for a mainstage show, the final one of our season, runs for i believe 3 weeks. So, they need to stand up to active use but over a relatively short period of time.