how to fabricate sheet metal?

Sheet metal fabrication is the process of forming metal sheets to the desired shape using different manufacturing methods. The completion of a product usually comprises of many steps – from cutting and bending to surface treatment and assembling.

Often times a variety of fabrication techniques can be used to achieve a similar end-result. But a right choice still exists, depending on the costs and needs.

The journey from sheet metal to metal product starts from CAD engineering. After making the models, each part goes through the necessary sheet metal fabrication processes. The most common ones are:

Laser cutting is the preferred option for cutting sheet. A very quick and precise cutting method that guarantees good results.

With thicker materials, plasma cutting may be used because of its quickness. This advantage is only evident with thicknesses upward of 10 mm though.

At the same time, cutting quality favours laser cutting. So we would advise to rather go with laser cutting services.

Shearing, or die cutting, refers to a process that cuts sheet metal without burning or melting it. Also, it does not produce any chips. In essence, shearing is not too different from cutting with scissors.

In shearing, a punch presses the workpiece against a fixed die or blade. The clearance between is such that the workpiece does not fit through, causing it to shear.

It is a great and cost-effective method to cut sheets into size whenever complex cuts are not necessary.

Punching is another way for cutting holes into a sheet. A metal punch hits the sheet, perforating it. It is suitable for large-scale production but not cost-effective for smaller jobs. The reason lies with the need for a separate tool for different cuts.

When it comes to actual engineering, there aren’t many metal components that elude the bending section of a fabrication shop. Press brakes are responsible for the folding of sheet metal parts.

This is probably the most difficult step in metal manufacturing because of the complexity of some bends. An engineer must be well acquainted with the limitations of metal bending to things that are actually producible.

Assembling is the ultimate or penultimate step when you want to fabricate a product. If assembling includes welding, the parts have to be clean – powder coating follows it.

Otherwise, parts are already powder-coated and adjoined using other methods, like riveting and bolting.

Powder coating is a process where an electrostatic powder is applied to a charged metal component. It is the preferred surface treatment method when no special requirements, like wear-heavy or acidic environments, apply to the construction.

Sheet metal design options are very flexible. Clients can express a need for certain functionality and sheet metal materials leave room for many different solutions.

Single prototypes to volume production are possible. Contemporary production methods, like 3D printing, provide quick lead times that are well-aligned with the needs in prototyping. These methods are, however, limited to prototyping only.

Sheet metal fabrication processes are suitable for a gradual transition from prototyping to large-scale production. Making prototypes sets the baseline and expectations for larger quantities by establishing the required infrastructure.

A wide range of surface finishes. Those include powder coating, painting, galvanising, plating, etc. This allows many different looks but also provides protection in different circumstances.

A variety of materials. The term sheet metal only tells us the range of thickness. But nothing about the material itself. Sheet metal can be of all types of metals – mild steel, stainless steel, aluminium, brass, etc.

Looking around, it is clear that sheet metal has a plethora of applications. There aren’t many home appliances, constructions, etc. that don’t incorporate any sheet metal parts. Still, different sheet metal groups have some specific uses. And we can go over them.

Cold rolled steel is comparatively cheap. As the name suggests, it is rolled at room temperature. Cold rolled steel is only limited to 3 mm thickness but has a nicer surface.

So it works well in applications that require nice smooth finishes. Some examples include home appliances, furniture, lockers and cabinets. Cold rolled steel is also used in larger structures, e.g. steel sheds and garages.

Hot rolled steel is formed in a heated state. Comparing hot rolled and cold rolled steel, hot rolling allows for easier forming, making the cost even lower. Also, thicker sheets at plates are only available as hot rolled for the same reason – ease of forming.

Hot rolled steel, however, does not have such accurate dimensions. After rolling, the metal cools down and shrinks. This results in concentrations of stresses that can warp the material and changes in measurements.

Stainless steel sheets are good in corrosive environments, where a combination with strength is important. Mostly used for all kinds of surgical instruments, cutlery, kitchen accessories, sinks, etc. Still, there are great industrial use-cases for storage tanks, valves, piping and the like.

Aluminium sheets may not be so common for every engineer because of its heavier price-tag. Still, aluminium finds a lot of use throughout the industry because of its standout qualities.

There are several processes that enable adequate cutting through sheet metal material without shear force. These techniques involve extreme heat, high pressure, vaporization, and abrasive blasting to shape the sheet metal fabrication parts. They include the following:

Sheet metal laser cutting involves using focused laser beams to melt metals in localized areas. Laser cutters are compatible with a long list of metals, ranging from non-ferrous metals to mild steel and stainless steel.

This technique consists of two concurrently running sub-processes. The first one involves concentrating a high-powered laser beam on the sheet metal. The material absorbs the laser beam’s thermal energy, making it vaporize.

At the same time, the second process involves a cutting nozzle providing blowing gas for laser cutting. This gas is usually oxygen or nitrogen. It helps to prevent the processing head from splashes and vapors during sheet metal fabricating engineering.

Plasma cutting is a thermal cutting process involving metal with ionized gas called plasma. The method uses substantial heat to cut the metal, which creates large burrs and an oxidized zone close to the cut area. In addition, it allows faster cutting, high precision, and repeatability in sheet metal manufacturing.

The plasma cutting tool works effectively only on electrically conductive sheet metals. Consequently, it is one of the most suitable methods for cutting conductive materials with medium aluminum thickness.

This cutting process involves using a high-pressure stream of water to cut metal sheets. Waterjet cutting is versatile and can cut various hard and soft materials using pressurized water and abrasive. It is ideal for cutting soft materials, metal foils, fabrics, or rubber. At the same time, it is suitable for cutting hard materials like copper, carbon steel, aluminum, and carbon steel.

The pressure involved is usually about 60,000 psi, with a 610m/s supply of velocity to cut through different types of metal sheets. However, waterjet cutting is a better substitute for the laser cutting technique.

The processes under this category cut metal materials using shearing force to overcome the metal’s ultimate shear strength. They usually involve using dies, punches, and shear presses to enable adequate cutting of the metal. The techniques here include the following:

Shearing is suitable for high-scale applications and cutting soft materials that don’t need clean finishes, like brass, aluminum, and mild steel. It cuts straight lines on sheet metals with a flat surface. The shearing method involves applying a shear force on the surface, causing the flat metal material to split at the cutting point.

This is often the ideal process for making straight edges on a metal sheet with rough edges. It is cost-effective for high-volume operations when manufacturing thousands of sheet metal fabrication parts within a short lead time. However, shearing may not be perfect for applications that need quality finishes due to the burrs and material deformations it causes.

Punching uses shear force to make holes in the sheet metal. In this sheet metal fabrication process, the scrap material is the material removed from the hole, while the final component is the remaining material on the die.

Punching is suitable for making cutouts and holes of different shapes and sizes. However, using the punching process can take much time. You have to match the dies and punching knives correctly.

Blanking is an ideal process for economic sheet metal fabrication. It involves removing a portion of sheet metal from a larger piece of the stock material using a blanking punch and die. The punch makes a “blanking force” through the sheet metal while the die holds it during the process.

The extracted material is the preferred component, while the remaining material on the die is the leftover black stock. This process is suitable for making economic custom parts due to its high repeatability, dimension control, and excellent accuracy.

• Thermal Cutting. Laser cutting is the preferred option for cutting sheet.
• Mechanical Cutting. Shearing, or die cutting, refers to a process that cuts sheet metal without burning or melting it.
• Punching. Punching is another way for cutting holes into a sheet.
• Bending.
• Assembling.
• Powder Coating.

Sheet metal fabrication refers to the turning of flat metal sheets into metal products and structures. Typically, this technique involves transforming different types of sheet metals into parts and components. It is also a versatile process that can create a wide range of metal components made from Aluminum, Steel, Stainless Steel, Copper, and Brass.

In sheet metal fabrication, different techniques are usually combined to produce the desired part. The basic processes include cutting, bending, punching, stamping, welding, and finishing. These techniques complement each other and play a vital role in the successful completion of a project.

What’s more, you are unlikely to go about your day without encountering sheet metal products. So, whether you’re at home, at work, or out and about, it’s highly likely that you find these products everywhere. This is a testament to the durability, versatility, and ubiquity of metal manufacturing.

Sheet metal fabrication can be complex and challenging to understand for many people, leading to unrealistic expectations and requirements for a project. It is important to note that the process of creating metal parts involves several steps from start to finish.

Every rapid prototyping process begins with an idea, and sheet metal design is no exception. It begins with basic concepts of what you want as a designer. You can put these ideas down roughly to provide realistic requirements for your project. It may also involve the designing of a 3D model of the desired component. The model often includes requirements for wall thickness, bend radii, hole orientation, bend allowance, and more.

After the completion of a 3D model, there is a need to create drawings for manufacturing. Before any work can begin, engineers need to develop blueprints. These blueprints will determine the specifications of the sheet metal needed to make initial drawings.

The drawings are what will be sent to the machine shop. The drawings often include all manufacturing information such as material selection, surface finishing, and more.

Along with other related calculations, the drawings will be rechecked to ensure they follow requirements and specifications. Following a DfM strategy helps to focus on simplifying the designs and possible reduction of part counts. Such analysis suggests standardizing parts for various applications.

Furthermore, engineers will get insights into developing designs that can be easily manufactured. Once the manufacturability analysis is complete, there will be a final shop drawing with in-depth calculations of stress/strain levels and load limitations. The information available therein will determine the sheet metal fabrication process.

Once there is a sheet metal design model, engineers carry out several processes to maintain the component’s geometry. These methods include cutting, bending, punching, stamping, and welding. Surface finishes also help to improve the aesthetics of the created prototype. It is important to carry out these steps one after the other. Rushing through the process or skipping one step may compromise the quality and integrity of the final product.

After developing the prototype, clients then evaluate the prototype to ensure that it meets their requirements. The testing may also involve using such components in real-life conditions. Also, evaluation can be done with users giving feedback on the products.

A prototype that passes testing and meets the required specification will go into full part production.

Each part must then go through the necessary metal fabrication processes to bring the designs to three-dimensional, functional components. The following covers the most common ones.

Cutting is typically the first step in sheet metal manufacturing. It involves using specialized tools, such as shears or laser cutters, to cut the metal sheet into the desired shape.

To be specific, cutting metal sheets is possible using shear, which uses shear forces to cut through the metal. There are three options involved in this type of cutting – shearing, punching, and blanking. On the other hand, sheet metal fabricators also carry out cutting without shear. This is the ideal process for industrial projects requiring precision cutting and faster lead times.

Besides, laser cutting is the preferred method for achieving high-quality cuts. Thus, we recommend you go to a professional sheet metal laser cutting service. We consider this process better suited to industrial applications. Laser cutting enables a high degree of precision (+/- 0.1 mm) and is time-efficient.

Bending can create a wide range of shapes and angles, from simple bends to complex shapes that require multiple bends. Additionally, bending is a cost-effective process that can make high-volume parts with consistent quality.

The process involves using a press brake machine to bend the metal sheet into a desired angle or shape. Despite how simple bending may seem to the untrained eye, it is a rather complex process that requires a highly skilled manufacturer. This is due primarily to the occurrence of “spring back,” which is the term for when metal inevitably tries to regain its original flat structure after bending. To overcome this problem, operators must overbend the part so that its spring-back angle is the desired angle.

Punching is a valuable technique for a wide range of metal sheets. During the punching process, fabricators press the punch through the metal sheet, creating a hole in the desired shape and size. And position the die underneath the metal sheet to collect the scrap material created from the hole. In addition to creating holes, punching can also make indentations in the metal sheet, and create features such as dimples or countersinks.

At RapidDirect, we offer CNC punching capabilities that can create holes up to 50 mm in diameter. This technique allows for precise and efficient hole punching, ensuring that the final product meets all required specifications and standards.

Welding is an essential process in sheet metal fabrication that involves joining metal pieces together to create a single part. There are various welding techniques available, including stick welding, MIG, and TIG welding.

Although the welding techniques differ in their approach, they all serve the same purpose of joining metal pieces together by melting the edges of the parts and adding filler material. This process creates a metallurgical bond between the pieces, fusing them together strongly. Welding is only necessary, of course, if a product comes with two or more separate components.

Assembling is the final step of the metal fabrication process that enables the creation of complex metal structures and components. By using the right methods and techniques, sheet metal fabricators can create high-quality products that meet all required specifications and standards.

Various methods, including mechanical fastening, welding, and adhesive bonding, can accomplish the assembly. Mechanical fastening uses bolts, screws, or other fasteners to secure the metal parts together. Welding creates a permanent bond between the parts, ensuring that the final product is strong and durable. Adhesive bonding is suitable for both temporary and permanent assemblies and is often used for creating lightweight structures or for applications where welding is not feasible.

Assembly can be a complex process that requires a high degree of skill and expertise. It is critical to assemble all parts correctly and securely to avoid any issues with the final product.

Ready to take your project to the next level with high-quality sheet metal components? Contact RapidDirect now.

Choosing the right material is a critical aspect of the fabrication process, as it can impact the final product’s quality, durability, and performance. With a wide range of materials available, each with its unique properties and advantages, selecting the right material can be a daunting task. This section provides insights into some of the most common materials for metal parts.

Right surface finishing can greatly enhance the final product’s appearance, durability, and functionality. Whether you are looking to enhance the appearance of your product or improve its performance, understanding the various metal surface finishing options available is essential to achieving your desired results.

Some of the surface finishing you can apply on sheet metal are:

Here are some of the important design features to consider when modeling a sheet metal part:

Other additional features to consider include hems, notches, tabs, curls, fillets, countersinks.

It is important to note some effective design tips for a better and rapid creation of components.

Specify hole sizes, alignment, and locations in the part design. Hole diameters lesser than the thickness of sheet metal may result in long burnish, high punch loading, and excessive burr. Therefore, hole diameters should be greater than the metal’s thickness.

Also, the distance between holes should be at least twice the sheet metal thickness. In cases where there must be a hole near the edge, spacing between the hole and the edge should be at least the sheet thickness.

Collars and bend relief near pierce areas help to strengthen components. Grain structures are also important to avoid cracks in parts with tabs or lugs. Lugs should not be parallel to the grain direction. This may lead to the formation of cracks. Rather, they should be perpendicular or a little less than 45 degrees toward the grain direction.

You should also keep the punch-to-die clearances large to avoid premature wearing out of the punch. Also, you tend to increase stiffness by putting beads on bends and chamfers at corners. This way, you can reduce the spring-back effect. A sheet metal part can easily maintain its flatness and strength by coining around flared holes.

Sheet metal fabrication is a science and an art. Its extensive range of nuances and techniques makes it important for a skilled metal fabricator to handle every project. Since you know the sheet metal design basics, let a professional service take care of the rest!

Sheet metal fabrication is a valuable prototyping and production method for making robust functional parts like panels, brackets, and enclosures.

However, unlike other manufacturing techniques, sheet metal fabrication actually comprises many different processes, all of which manipulate the sheet metal in different ways. These different processes may involve cutting the sheet metal, shaping it, or joining different pieces of it together.

This guides look at the main sheet metal fabrication processes and explains how they work and what they are used for.

Sheet metal fabrication is a set of manufacturing processes for turning sheet metal into functional parts. For this guide, we have divided the processes into three categories: cutting, deformation, and assembly.

Common sheet metals include steel, stainless steel, aluminum, zinc, and copper, and these materials usually come in gauges between 0.006 and 0.25 inches (0.015 and 0.635 centimeters) thick. Thinner gauges are more malleable, while thicker ones may be more suitable for heavy-duty parts with strenuous applications.

For partially flat or hollow parts, sheet metal fabrication can be a cost-effective alternative to processes like casting and machining. The process is also quick and produces minimal material wastage.

Sheet metal fabrication is widely used for industrial and consumer parts and in specialist industries like automotive, aerospace, energy, and robotics.

One of the three main ways to manipulate sheet metal is to cut it. In this sense, sheet metal fabrication can be considered a subtractive manufacturing process (like CNC machining), because usable parts can be made by simply removing sections of material.

Manufacturers can cut sheet metal using a variety of different pieces of machinery, some of which are unique to sheet metal fabrication.

One of the key methods for cutting sheet metal cutting is laser cutting. A laser cutter uses a powerful laser intensified with a lens or mirror. It is a precise and energy-efficient machine suitable for thin or medium gauges of sheet metal but may struggle to penetrate the hardest materials.

Another sheet metal cutting process is water jet cutting. Water jet cutting is a sheet metal fabrication method that uses a high-pressure jet of water (mixed with an abrasive substance) to cut through the metal. Water jet cutters are particularly useful for cutting sheet metals with a low melting point since they do not generate heat which could unduly deform the metal.

A third sheet metal cutting option is plasma cutting. A plasma cutter creates an electrical channel of ionized gas which forms a jet of hot plasma that easily penetrates even thick gauges of sheet metal. Although less accurate than laser or water jet cutters, plasma cutters are fast and powerful with low setup costs.

These three cutting machines can be used on other materials besides sheet metals, but there are some techniques used solely for sheet metal fabrication.

The process of punching (sometimes called piercing), for example, creates precise holes in sheet metal using a punch and die. The sheet metal is placed between the two components, and the punch forces itself through the metal to reach the die. In the punching process, the punched circular pieces of removed material are turned into scrap, but these circular pieces can also be used as new workpieces: this is called blanking.

When creating many holes, similar equipment can be used for the perforation of the sheet metal.

Another major category of sheet metal fabrication processes is sheet metal deformation. This group of processes contains myriad ways to change and manipulate sheet metal without cutting into it.

One of the main deformation processes is sheet metal bending. Using a machine called a brake, a sheet metal company can bend sheet metal into V shapes, U shapes, and channels to an angle of up to 120 degrees. Thinner gauges of sheet metal are easier to bend. It also possible to do the opposite: sheet metal manufacturers can remove the horizontal bend from strip-shaped pieces of sheet metal with the process of decambering.

The process of stamping is another deformation process, but it can also be thought of as a subcategory of its own. It involves the use of a hydraulic or mechanical stamping press equipped with a tool and die, and its operation is similar to punching — though the material does not necessarily have to be removed. Stamping can be used for specific tasks like curling, drawing, embossing, flanging, and hemming.

Spinning is a sheet metal fabrication process unlike other deformation techniques in that it uses a lathe to rotate sheet metal as it is pressed against a tool. The process looks similar to CNC turning or even pottery spinning, and it is useful for creating rounded sheet metal parts: cones, cylinders, etc.

Less common sheet metal deformation processes include wheeling, which is used to make compound curves in sheet metal, and rolling, in which sheet metal is fed between a pair of rollers to reduce its thickness (and/or increase consistency in thickness).

Some processes sit halfway between cutting and deformation. For example, the process of sheet metal expanding involves cutting multiple slits in the metal then stretching the sheet open like an accordion.

Sheet metal cutting and deformation are two ways of forming sheet metal. A third way is assembly, either by using common fasteners or by other methods.

Although it is not always considered a fabrication process, the assembly of disparate components of sheet metal parts using fasteners bolts, screws, and rivets is an important part of the overall manufacturing process. Other sheet metal fabrication processes like punching may be carried out explicitly to make holes for rivets and other fasteners.

Sheet metal components may also be joined together using the process of welding, in which heat is applied to melt a section of the metal where it joins with another component. The melted metal of the two components fused to form a solid connection. Common sheet metals like stainless steel and aluminum have good weldability, although different metals may weld better with certain types of welding: arc, electron beam, resistance, etc.

If you’ve already designed sheet metal parts, chances are you have a good idea of the fabrication processes that will be used to realize the design. In fact, some CAD utilities like Autodesk Fusion 360 and Dassault Systemes Solidworks let you create features that correlate with physical sheet metal manufacturing processes like bending and stamping.

Regardless of your level of experience, the sheet metal experts at 3ERP can help you finalize your designs and choose between similar processes like laserjet cutting and water jet cutting.