What is custom sheet metal fabrication and Why Do We Use Them?

As a species, we've been using metal since around 4,000 B.C. ' and maybe even earlier.

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With time, our understanding of metallurgy has improved, making way for new possibilities. Modern metal fabrication companies have a huge range of capabilities, and metal parts are vital for all kinds of industries all over the world. Custom sheet metal is one of the most popular types of metal parts, and it has a wide range of applications.

In this guide, we'll take an in-depth look at custom sheet metal fabrication so you can understand what it's all about. Keep reading for more.

What Is Custom Sheet Metal Fabrication?

Sheet metal fabrication encompasses various processes that are used to form a functional part. This includes things like bending, cutting, and punching. The final product is a piece of sheet metal that's custom-built to precise specifications for a specific purpose.

How Does Metal Fabrication Work?

There are three main steps to the sheet metal fabrication process.

First, a 3D model of the intended piece is made using CAD (computer-aided design) software. Second, this file is converted into machine code and transferred to a specific machine. Finally, the machine uses various processes to form the piece to the exact specifications set out.

Each part made using this process is formed from a single piece of sheet metal. This ensures it has a uniform thickness, and this can be anywhere from 0.5mm to 6mm. Parts can be manufactured up to 20mm thick, but anything that has a thickness greater than 6mm is considered plate rather than sheet.

Custom Sheet Metal Fabrication Uses

There are plenty of applications for sheet metal. It's used in industries including:

• Automotive
• Aerospace
• Energy
• Construction
• Telecommunication
• Electronics
• Lighting

Fabricated sheet metal is widely used for building structures such as housings, enclosures, cabinets, and brackets. Custom fabrication is incredibly flexible and precise. Whatever needs an organization has, a reliable sheet metal fabrication company will be able to produce the exact parts required.

Benefits of Custom Sheet Metal Fabrication

There are many products and applications that rely on sheet metal fabrication ' but they could make use of other products and processes. Custom sheet metal is often the first choice as it offers several benefits that make it more suitable than the alternatives available.

Better Designs

Customization is vital for all kinds of projects. Modern technology allows for a high level of customization when it comes to sheet metal fabrication.

Whatever project you have in mind, there may be some standard parts that you need, as well as some very specific parts. A custom sheet metal fabricator can make varied parts to meet your exact requirements. This ensures you don't have to compromise or make substitutions and can do exactly what you need to.

Reduced Costs

Cost is an important factor in any project, and being able to reduce costs should always be a goal. With that in mind, you don't want to sacrifice quality to save some money.

Custom sheet metal fabrication is typically quite cost-effective. One of the reasons for this is that you can buy custom parts directly from the fabricator.

If you buy standard parts from a supplier, you'll pay more as there's a middleman. You'll typically get a better deal with custom sheet metal fabrication ' especially if you need multiple parts.

Faster Delivery

Another advantage of getting parts directly from a fabricator is that it will save time. The more points there are in a supply chain, the longer it will take to get your parts.

This is as short as a supply chain can be, so it's often the fastest way to get what you need. You can work directly with a custom sheet metal fabricator to benefit from fast turnaround times and more streamlined processes.

Higher Quality Parts

Quality is an important factor ' especially in certain industries such as aerospace and automotive. Mass-produced parts are typically far lower quality than custom-fabricated parts. Getting your parts from a professional custom sheet metal fabricator will ensure they meet high standards and are suitable for whatever application you require.

Types of Custom Sheet Metal Fabrication

There are several types of sheet metal fabrication. The services you need will depend on the part(s) you want.

Cutting

Laser cutting uses a high-energy beam to vaporize metal and form a cut. It's fast, precise, and reduces the risk of the metal warping.

Water jet cutting is another option that cuts metal using a high-pressure jet of water (sometimes mixed with an abrasive substance). This is an ideal method for metals that have a low melting point, as high temperatures can cause deformation.

Plasma cutting is the most powerful putting option, which uses an electrical channel of extremely hot, electrically ionized gas (plasma). This is ideal for thicker material, but it's less precise than laser or water jet cutting.

Guillotining is a somewhat different cutting method, but it can still produce clean, accurate cuts. It's done by feeding the sheet between two blades that are compressed together. It's one of the fastest and cheapest cutting methods, but it may leave slight deformation on the edge of the material.

Punching

A die can punch through metal sheets at a high speed. This perforates the sheet and can be done in custom shapes, though circle, square, and rectangle dies are common as standard. Custom dies are more suitable for high-volume production due to the cost of fabricating the die.

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Bending

A press brake is a machine that can bend sheet metal into functional parts. The depth of the punch will determine the angle of the bend, and this can be controlled to a high degree of accuracy.

Assembling

Assembling involves using mechanical fasteners like screws, bolts, and rivets to assemble sheet metal components. Welding can also be used for this to permanently fuse multiple parts together.

Custom Sheet Metal Fabrication Services

Custom sheet metal fabrication allows fabricators to produce a varied range of parts for almost any application. If you have a project that requires high-quality custom parts, a sheet metal fabricator will be able to supply them for you.

The traditional industry of custom sheet metal fabrication was a sum of straightforward processes. Metal fabrication meant welding, cutting, machining, and assembly.

The industry has evolved by magnitudes since da Vinci's first sketch of a modern sheet metal technique in . The industry also represents the foundation of aerospace, construction, energy, and the automotive industry.

In response, metal shops have adapted by diversifying their portfolio. In this article, you will learn what metal fabrication is and how the process works.

What is Metal Fabrication?

The exported metal fabrication industry in the U.S. made more than $40 billion dollars in . Sheet metal fabrication is projected to grow through to . You use many products, daily, that form parts of the metal fabrication sector. Mailboxes, roof gutters, casings, and air-conditioning ducts/furnace flues are all examples.

Metal fabrication takes sheet metal from its recycled or manufactured state into new products. Most metal fabricators work with sheet metal. Sheet metal is industry-standard sheets that are cut, folded, and shaped into end products. Sheet metal is used for both mass production and custom products.

How Does Metal Fabrication Work?

Metal fabrication uses complex machinery and manufacturing processes to produce high-quality products. Sheet metal typically arrives from a wholesaler or metal mill. Sheet metal is cut, folded, formed, bent, engraved, and more. Standard tools that a metal fabricator will work with include lasers, punch presses, and press brakes.

High-quality products require clean cuts and no discoloration so will often be manufactured using a laser cutter. Intricate patterns are also better performed with a laser cutter. Laser cutting can handle a wide variety of metals, including carbon steel and titanium.

Metal fabrication involves many different types of metals. More than 3,500 different grades of steel alone exist, over 75 percent of which have been developed in the last twenty years. Metal is highly adaptable. A wooden framed house must be crafted from undamaged recycled pieces and fresh timber. Yet, four recycled steel cars can be fabricated into a 2,000 square foot house.

The Metal Fabrication Process

Product engineers start the process by sending out plans and sketches to different fabricators to get quotes. The fabricators come up with a cost estimation and timeline based on their experience and the potential project.

From these quotes, product engineers select one fabricator for that particular end product. Some end products can have several different fabricators involved in different elements. The fabricator then orders materials for the project, typically sheet metal, bars, rods, and tubes.

Once the parts arrive, the fabricators begin to work. For custom sheet metal fabrication, the fabricators may play a role in the design process as unique products need specific techniques to achieve the right result. Highly skilled fabricating shops like All Metals Fabricating are usually able to produce any product after deducting the best manufacturing process for it.

The final step of the manufacturing process involves assembly and finishing. These processes prepare the product for use, whether with joining techniques or coatings. Methods like graining with a belt sander or putting a vibratory sanded finish are two raw metal finish options.  Other common finishes include powder coated or various plating specifications. 

The Processes Involved

The process of metal fabrication involves special machines. Some of which are unique to metal materials. In total, there are many processes involved in metal fabrication. Here are a few examples of the processes involved in sheet metal fabrication:

1. Cutting - Shear, CNC Punch presses, Lasers, Waterjet, plasma 
2. Bending - Press brakes, folding machines, panel benders
3. Welding - Mig, Tig, robotic, laser 
4. Hardware insertion - Haeger Presses
5. Grinding & Graining - cleaning up welds, belt sanding to put nice grained finish

The Benefits of Metal Fabrication

Metal fabrication is a highly skilled and potentially complex manufacturing process. Fabrication is expensive, so it is often reserved for high-quality products. Below is a shortlist of essential reasons why metal fabrication could be the right choice for your manufacturing project.

The final appearance of your product is the key to profit. Many high-quality manufacturers such as tech companies have opted for a metal design. Metal gives smartphones and computers durability and a modern, sleek look.

The durability of metal products is naturally superior to plastic. Not to mention, metal can withstand higher temperatures. If the manufacturer has taken into account expansion under heat, the heat will usually not damage the product.

Especially in high volume manufacturing, metal is far more cost-efficient than other processes. Process replication can reduce the manufacturing cost per unit. The method of sheet metal fabrication is also more versatile, allowing for a wider variety of approaches. Other materials cannot withstand many processes which can be carried out on metal.

Custom Sheet Metal Fabrication

Metal fabrication is a complex manufacturing process, but it is highly versatile and adaptable. With the right fabricator, the process can result in a high-quality, distinguished product. Ultimately those products can be cheaper to manufacture. Not to mention, sheet metal fabrication gives you more control over the end product.

Custom sheet metal fabrication is highly flexible. Still, some processes will not work with certain materials or be limited by product design. Therefore, it is crucial to contact a professional metal fabricator for advice and guidance during the design process to confirm your plans.

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