What Is Sheet Metal Fabrication?

Sheet metal fabrication is a manufacturing process that involves cutting, bending, and assembling thin metal sheets into various shapes and products. This versatile process is used to create parts and structures from a variety of metals, such as steel, aluminum, copper, and brass. Sheet metal processing has the characteristics of high precision, lightweight, diversity, and high efficiency, which require selecting appropriate materials, designing reasonable processes, and implementing strict quality control. 

Thingyfy can provide sheet metal parts in any quantity from low-volume, high-mix prototypes to high-volume production runs. Thingyfy offers competitive custom sheet metal fabrication pricing for low-volume prototypes and cost savings for high-volume production runs.

How does sheet metal fabrication work?

The manufacturing process uses specialized machinery to achieve the correct specifications. For example, this machinery includes bending machines and cutting torches. We typically work with metals such as steel, stainless steel, copper, brass and aluminum, but our team has experience with many other materials as well.

The sheet metal manufacturing process begins with a computer-aided design (CAD) model, where engineers create a detailed blueprint of the part or product to be manufactured. This design serves as a guide throughout the manufacturing process. These designs are made to your exact specifications. We then cut the metal using techniques such as shearing, roll forming, punching, blanking, metal stamping and laser cutting.

Once the cutting is complete, press brakes, punches and dies are used to form corner bends and features into the raw material. If any assembly or post-processing is required, our sheet metal fabricators will weld, add inserts or finish the part.

Sheet metal fabrication leaves little room for error, and precision is required at every step, from cutting and bending to powder coating. Our quality processes mean we can detect and prevent errors early, so you get a consistent product every time.

Types of sheet metal fabrication

Sheet metal fabrication involves various processes to shape and form metal sheets into desired parts and structures. Here are sheet metal fabrication services from Thingyfy:

1. Laser Cutting

   - Laser cutting is usually the first step in sheet metal fabrication. A high-powered laser beam precisely cuts the flat metal sheet into the desired shapes and sizes according to the design specifications.This process allows for accurate and clean cuts, especially for complex shapes and patterns. It's ideal for preparing the metal pieces for the next stages of fabrication.Commonly used on materials like stainless steel, aluminum, and carbon steel.

2. Bending

   - Press Brake Bending: Involves a press brake machine that bends the metal sheet at specific angles.

   - Roll Bending: Uses a set of rolls to bend the metal into cylindrical or conical shapes.

   - Air Bending: The metal is placed over a die and bent by a punch without full contact between the metal and the die.

3. Punching

   - Turret Punching: Uses a punching machine with a turret containing various tools to punch holes or shapes in the metal sheet.

   - CNC Punching: Involves computer-controlled punching machines that can create complex patterns and shapes.

4. Forming

   - Stamping: Uses a die to press the metal into a specific shape, often used for mass production of parts.

   - Deep Drawing: A process where the metal sheet is stretched into a cavity to form deep, hollow shapes.

   - Spinning: Rotates the metal sheet at high speed while pressing it against a form to create round, symmetrical parts.

5. Joining

   - Welding: Involves fusing metal parts together using heat or pressure, with methods like MIG, TIG, and spot welding.

   - Riveting: Fastens sheets together using metal pins called rivets.

   - Brazing and Soldering: Uses a filler material to join metal parts at a lower temperature than welding.

6. Finishing

   - Deburring: Removes sharp edges or burrs left from the cutting process.

   - Polishing: Smoothens and shines the metal surface.

   - Powder Coating: Applies a protective and decorative finish to the metal surface using powdered paint.

   - Anodizing: Enhances corrosion resistance and aesthetic appearance by creating an oxide layer on the metal surface.

7. Assembling

   - Combines various fabricated parts into a finished product using techniques such as welding, riveting, or fastening with screws

These types of sheet metal fabrication processes are used across various industries, including automotive, aerospace, electronics, and construction, to create everything from small components to large structures.

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Estimating sheet metal fabrication costs

When estimating sheet metal fabrication costs, you can employ the following methods to reduce the cost of manufacturing sheet metal parts:

1. Optimize Material Usage:

   - Nesting Software: Utilize nesting software to optimize the layout of parts on the metal sheet, minimizing waste.

   - Material Selection: Choose cost-effective materials that still meet the design and functional requirements.

2. Simplify Design:

   - Reduce Complexity: Simplify the design of parts by reducing the number of bends, holes, and complex features, which can lower machining and labor costs.

   - Standardize Components: Use standard sizes and components where possible to reduce custom fabrication needs.

3. Minimize Secondary Operations:

   - Limit Finishing Processes: Reduce or eliminate finishing processes like polishing, coating, or painting if they are not essential for the part's function.

   - Reduce Assembly Steps: Design parts that require fewer assembly steps or can be assembled more efficiently.

4. Increase Production Volume:

   - Bulk Ordering: Increase the production volume to take advantage of economies of scale, which can reduce the per-unit cost of manufacturing.

   - Group Similar Parts: If possible, group similar parts into a single production run to optimize machine setup and reduce downtime.

5. Choose Efficient Fabrication Methods:

   - Laser Cutting vs. Waterjet: Select the most efficient cutting method based on the material and thickness. For example, laser cutting may be faster and more cost-effective for thinner sheets.

   - Use Advanced Machinery: Invest in or work with facilities that use advanced, automated machinery that can reduce labor costs and increase precision.

6. Outsource Strategically:

   - Find Competitive Suppliers: Work with suppliers who offer competitive pricing without compromising quality.

   - Offshore Manufacturing: Consider outsourcing to regions where labor and material costs are lower, though this must be balanced with potential logistics costs.

7. Reduce Lead Times:

   - Streamline Supply Chain: Work with suppliers who can provide quick turnaround times, reducing the overall lead time and associated costs.

   - Inventory Management: Maintain an optimal inventory level to avoid rush orders, which can be more expensive.

By implementing these strategies, you can effectively reduce the cost of sheet metal fabrication while maintaining the quality and functionality of the parts.

Sheet Metal Materials Available at Thingyfy

Sheet metal fabrication can utilize various metals such as steel, aluminum, brass, copper, stainless steel, titanium, and many other metal sheets to create custom parts. Some sheet metal fabrication machines, like waterjet cutters, are designed to handle thicker metal materials, while others, such as laser cutters, are optimized for working with thinner sheet metals.

Why Use Sheet Metal Fabrication?

Sheet metal fabrication is widely used across various industries due to its versatility, durability, and cost-effectiveness. Here are some key reasons why sheet metal fabrication is essential:

1. Customization: Sheet metal fabrication allows for precise customization of parts and components, making it ideal for industries that require specific designs and measurements, such as automotive, aerospace, and electronics.

2. Durability: Metal is inherently strong and resistant to wear, corrosion, and extreme temperatures, making sheet metal products long-lasting and reliable.

3. Cost-Effective Production: The process is highly efficient, especially for large-scale production runs. Advanced techniques like CNC machining and laser cutting reduce waste and minimize material costs.

4. Speed and Efficiency: Modern sheet metal fabrication techniques allow for rapid production of parts, which is crucial for industries that require fast turnaround times.

5. Material Variety: Sheet metal fabrication can work with a wide range of materials, including steel, aluminum, copper, and more, providing flexibility in design and application.

6. Lightweight: Despite its strength, sheet metal can be fabricated into thin, lightweight components, which is advantageous for applications where weight is a critical factor.

7. Sustainability: Metal materials used in sheet metal fabrication are often recyclable, contributing to sustainable manufacturing practices.

Advantages of Sheet Metal Products

Sheet metal products offer numerous advantages that make them a preferred choice in various applications:

1. Strength and Durability: Sheet metal products are known for their high strength and ability to withstand harsh environments, making them suitable for heavy-duty applications.

2. Versatility: These products can be easily molded, cut, and shaped into complex forms, allowing for a wide range of designs and applications, from simple enclosures to intricate mechanical parts.

3. Precision: Advanced fabrication methods, such as laser cutting and CNC machining, ensure high precision in the production of sheet metal parts, resulting in consistent quality and tight tolerances.

4. Cost-Effectiveness: The efficiency of the fabrication process, coupled with the longevity of the products, makes sheet metal a cost-effective solution for both manufacturers and end-users.

5. Aesthetic Appeal: Sheet metal products can be finished with various coatings and treatments, such as powder coating or anodizing, to enhance their appearance and protect against corrosion.

6. Easy to Repair: In case of damage, sheet metal parts can often be repaired or replaced easily, reducing downtime and maintenance costs.

7. Scalability: Sheet metal fabrication is well-suited for both small and large production runs, making it adaptable to different project needs.

8. Recyclability: Many sheet metal products are made from recyclable materials, contributing to environmental sustainability and reducing waste in manufacturing.