Jul. 21, 2025
Hardware
Sheet metal fabrication is a highly versatile manufacturing process that creates complex parts and structures from metal sheets. From cellphones and kitchenware to submarines and rockets, numerous industries utilise this process to create a wide range of products and technologies that shape our daily lives and facilitate technological advancement. This sheet metal fabrication guide comprehensively explores sheet metal fabrication, exploring everything you need to know about the process.
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Sheet metal fabrication is the process of creating parts, components, assemblies, and structures out of sheet metals, encompassing multiple operations. As the name implies, this manufacturing process is exclusive to metals, with the raw materials being flat metal sheets of various sizes, thicknesses, and metal types, depending on the project and the final product’s application.
In this manufacturing process, flat metal sheets undergo various processing stages to achieve desired sizes, shapes, patterns, and geometries. Sheet metal fabricators cut, form, and assemble pieces of flat metal sheets to create various parts and structures. These include containers, chassis, enclosures, frames, brackets and mounts, barricades, vents, and panels.
Sheet metal fabrication comprises various processes and operations. These processes can be classified into the following manufacturing stages:
While there are many types of 3D printing, They all follow the same broadly defined steps to create a part. The actual printing is just one step, with the complete 3D printing manufacturing process from conceptualisation to the final product involving five steps.
The sheet metal design stage involves creating 3D models of the structures or parts to be fabricated. In this stage, designers use CAD (Computer-Aided Design) modelling software to create digital replicas of the final product. These may be single models of standalone parts or entire assemblies. Designers meticulously apply dimensions, tolerances, and surface finishes to the model, accounting for part features and position, materials, and potential fabrication processes.
The design stage, creating 3D models, serves two crucial functions. The first is generating machine-readable language, G-code (Geometric code), for CNC (Computer Numerical Control) manufacturing. Modern sheet metal fabrication operations, such as cutting and bending, typically utilise CNC machines. These machines are controlled by embedded computers that dictate various aspects of the operation, enabling highly accurate execution. After designing a model, the designer imports it into CAM (Computer-Aided Manufacturing) software that analyses the model and generates the corresponding G-code, containing specific instructions on producing the part. Operators then program the computer using the G-code.
In addition to facilitating CNC manufacturing, the design stage ensures the feasibility and manufacturability of a sheet metal fabrication project. There are numerous factors that sheet metal fabricators must consider and rules they must follow to fabricate a part successfully. These factors and rules relate to the thickness of the workpiece, type of metal, geometries and shapes, positioning of features, and many more. The sheet metal design stage also guides the fabricators on the appropriate processes and operations required to produce a specific part or structure. See our comprehensive sheet metal design guide to learn everything you need to know about designing for fabrication.
The fabrication stage comprises various operations and processes performed on the workpiece(s) to achieve the final product. These operations include cutting, bending, forming, heat treatment, welding, joining, and assembly. Depending on the project, some of the operations may be optional. There are also various setup stages in which operators prepare the machines for use. Operators may also need to preprocess the material. The various sheet metal fabrication operations are later explored in this sheet metal guide.
Post-processing in sheet metal fabrication comprises operations carried out after fabrication that enhance the quality of the fabricated part. Post-processing operations may be aesthetic, improving the part’s appearance, or functional, creating desired properties and characteristics. The most common post-processing operations in sheet metal fabrication are heat treatment, such as annealing, tempering, and hardening, and surface finishing, such as coating, anodising, and electroplating.
Sheet metal fabricators produce metal parts and structures from metal sheets using numerous operations and processes. These operations are classified into the following:
The application of these processes may vary by project. For example, a sheet metal fabrication project may require only cutting and finishing or cutting, assembly, and post-processing. Similarly, while fabricators typically perform these operations in this order, some projects may require forming before cutting or finishing before assembly.
Sheet metal cutting is the process of slicing through the workpiece. This operation has two main functions: cutting away parts of the workpiece to achieve a shape or size and cutting into the workpiece to create a pattern. The cutting technologies predominantly applied in sheet metal fabrication include:
These cutting methods offer different advantages in terms of accuracy, precision, speed, and cutting abilities.
A highly pressurised water jet cuts through the workpiece during waterjet cutting. The stream of water flows through a tiny nozzle, further increasing its force and stream velocity, with some machines capable of up to 620 Mpa pressure. At these speeds and pressure, the stream acts as a physical blade. The nozzle focuses the jet stream onto the metal workpiece, seamlessly cutting through it on contact.
Waterjet cutting is a CNC process, with computers controlling the movement of the nozzle, the water pressure, and the flow activation. This process may utilise plain water or water containing abrasive particles. Depending on the material, waterjet cutting can cut through various thicknesses of metals up to 300 mm (cutting speed and accuracy start to decrease above 100 mm). One of the advantages of waterjet cutting for sheet metal fabrication is that it is a cold-cutting process. Therefore, it doesn't cause heat-related issues.
Laser cutting uses a high-energy laser beam generated by exciting lasering materials to cut through metal workpieces. Optics in the machine beam down the laser through a cutting head onto a workpiece below. The laser cuts the workpiece by melting through it. CNC controls the laser's movements and intensity.
Laser cutting can cut through a workpiece or cut out patterns. Depending on the material, this process can cut various thicknesses of metals up to 30 mm.
In this sheet metal fabrication process, plasma generated from highly energised gas is the cutting medium. Unlike waterjet and laser cutting, this process is only compatible with conductive materials like metals. This is because plasma cutting is an electrical process. When plasma ejects the nozzle and contacts the workpiece, an electrical arc forms between them, creating enough heat to melt through it.
CNC controls the activation, intensity, and movement of the plasma.
Mechanical cutting describes operations that utilise a physical cutting tool to cut through the workpiece.
Waterjet vs laser vs plasma cutting
Sheet metal forming is the controlled application of force to the workpiece to change its shape or achieve a specific geometry. This crucial sheet metal fabrication process involves forming sheet metal through various techniques to create complex shapes and structures without material removal. Sheet metal forming techniques include bending, stamping, stretching, rolling, and deep drawing.
The processes require different specialised equipment and create varying geometries. Their application depends on the desired shape and structure of the end product. A combination of these processes or multiple executions of a particular process may be required to create a part. Sheet metal fabricators may preheat the workpiece to increase its workability.
Bending involves folding the workpiece at specific points. The sheet metal workpiece is deformed along a straight axis to form a desired angle or shape. Various bending techniques and machines exist. One of the most common bending techniques is V-bending. In this technique, a punch forces the edge to be bent into a V-shaped die. Other bending techniques include U-bending, Air bending, and Roll bending.
Bending is one of the most predominant sheet metal forming operations and can create circular, cubic, and parametric shapes. This process is also critical in achieving the final geometry and has numerous considerations that vary by material thickness, bend orientation and angle, and intended shape.
Sheet metal stamping is the process of pressing a shape into a workpiece or vice versa. In this process, sheet metal fabricators place a blank, flat workpiece in a stamping press. The press contains a die with the desired shape. When the stamping force is applied, the metal is deformed into the shape of the die.
Rolling is a sheet metal fabrication operation that involves passing the workpiece through a set of rollers. The rollers compress the workpiece as it passes through, reducing its thickness. Fabricators use this operation to achieve uniform thickness or to make the workpiece thinner. Certain applications require passing the workpiece through different rolling machines with progressively lower distances between the individual rollers to create lower thicknesses. Rolling produces flat, straight geometries. It can also be used to create curves.
In deep drawing, a punch forces a blank sheet metal into a specifically shaped hollow die. The punch and die are shaped in a way that they fit. For example, if the die is a cylindrical hole, the punch will be cylindrical with a diameter close to the die's but with clearance. The blank is placed in between the punch and die. When the force is applied, the punch stretches and draws the workpiece into the hollow die, and the workpiece takes the shape of the die. Sheet metal fabricators use drawing to create hollow container-like parts that are round or have rounded edges.
In sheet metal spinning, operators clamp a flat metal disc or tube onto a lathe-mounted rotating mandrel. As the mandrel and workpiece rotate at high speeds, a forming tool progressively presses the workpiece against the mandrel at specific points, gradually forming it into an axially symmetrical shape. Sheet metal spinning forms cylindrical, conical, and other round geometries.
Joining and assembly encompasses techniques, operations, and processes used to assemble processed workpieces to form a final sheet metal part or structure. Typical sheet metal joining operations and techniques include.
Sheet lamination is compatible with thermoplastics, sheet metals, paper, glass, and composites such as carbon fibre and Kevlar.
Sheet metal welding is the process of joining metal parts by melting the joint edges and allowing them to fuse on cooling. In this sheet metal fabrication process, operators position the parts with the weld edges in contact. The operator uses a high-energy thermal source to raise the temperature at the edges to their melting point, adding a filler material to the molten weld pool. Upon cooling, the edges solidify, creating a solid permanent joint.
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Various types of welding techniques exist. These techniques vary by the energy source and consumables used. The most common in sheet metal fabrication are TIG (Tungsten Inert Gas) welding and MIG (Metal Inert Gas) welding.
Also known as Gas Tungsten Arc Welding, TIG welding uses a non-consumable tungsten electrode to produce the weld. An inert gas, typically argon, shields the weld area from contamination. TIG welding is known for its precision and is often used for welding thin materials and applications requiring high-quality welds.
On the other hand, MIG, also known as Gas metal arc welding, utilises a continuous wire electrode fed through a welding gun. It typically uses a mix of argon and carbon dioxide as shielding gas to protect the weld area from contamination. MIG welding is known for its speed, ease of use, and ability to weld thick cross-sections of steel and ferrous alloys.
Brazing involves using a filler metal to bond workpieces together without melting the base metals. In this process, the operators place the workpieces together. They then melt a filler metal, with a lower melting point than the base metals, over the joint. The molten filler metal flows into the gaps of the workpieces’ joints and bonds them together upon cooling.
Soldering follows the same principles as brazing, with the difference being the temperatures at which they occur. Brazing is done at temperatures above 450⁰C. While soldering is performed below 200⁰C. Both processes must be below the temperature of the base metals.
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Fastening involves using hardware fixtures to hold sheet metal parts together mechanically. These fixtures may be incorporated into the workpiece or be external.
Threaded holes and screws: Operators create threaded holes by tapping pre-drilled holes in the workpieces. They then join parts by aligning the holes and screwing them together using screws. Other threading methods include the use of threaded inserts.
Bolts and nuts: In this method, operators drill non-threaded holes through the workpieces at the points where they are to join. To fasten them, the operator aligns the holes, passes a threaded bolt through and attaches the nut on the other side.
Rivets: The riveting process is very similar to using bolts and nuts. However, it uses non-threaded cylindrical pins with wider heads known as rivets instead. The rivet is inserted through the holes and extends out of the other end. An operator uses a hammer to flatten the other end of the rivet to be wider than the hole, securing it in place.
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Adhesive bonding is the use of industrial-grade adhesives to join parts together. This sheet metal assembly technique can join sheet metal with other materials such as wood and plastic
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Sheet metal fabricators need to follow specific guidelines to ensure seamless fabrication. Designers apply most of these guidelines during the design stage, while the fabricators execute them during production. The guidelines cover various aspects of cutting, forming, and bending, including rules on dimensions, tolerance, how to create various features, feature placement, material considerations, and efficiently performing processes.
There are numerous other rules and guidelines involved in sheet metal fabrication. Many of which relate to specific features and fabrication processes. See our comprehensive sheet metal design guide for everything you need to know about designing sheet metal parts.
Post-processing refers to operations performed on a fabricated structure or part to bring it to a desired physical state or induce certain characteristics. It improves the overall quality of the finished product and may be functional or aesthetic. Sheet metal post-processing operations can be classified under heat treatment and finishing.
Heat treatment is the controlled heating and cooling of the part or structure. Sheet metal fabricators use heat treatment to receive stresses that form during fabrication and elicit desired properties. These operations always come before finishing operations. Common heat treatment operations are:
Finishing typically describes post-processing operations directed at the surface of the part. These operations alter colour, surface finish, and surface properties. Operators perform finishing operations to improve aesthetics, provide protective coatings, and induce certain properties. Common sheet metal finishing operations include:
Note that while post-processing operations are typically performed after assembly, some projects may require some of the operations before assembly. For example, a sheet metal fabricator is likely to powder coat a part before assembling it with screws.
Bead blasting involves spraying a continuous, pressurised stream of tiny abrasive glass or plastic beads at the part's surface. This stream knocks off loose particles, removes burrs and imperfections, and smoothes out the surface, leaving a uniform satin or matte surface. Sheet metal fabricators predominantly use bead blasting for aesthetic finishing and as a preliminary surface preparation process for other finishing operations. Bead blasting is compatible with small to large-sized parts.
In the tumbling process, the part is placed in a vat of vibrating granular tumbling media over a specific period. The media progressively knocks off impurities and smoothes the part as the vat vibrates. Tumbling is limited to small to medium-sized parts, depending on the size of the vat.
Powder coating involves applying a thin layer of electrostatic, coloured polymer powder to the part’s surface, followed by curing. This process creates a smooth, coloured, visually appealing protective layer on the part, thus improving aesthetics and providing corrosion and weather resistance.
Powder coating is a more durable option than painting and is compatible with all metals. However, it cannot be easily applied to internal surfaces.
Anodising is an electrochemical process that creates a layer of stable oxide coating on a part or structure. In this process, the part is submerged as an anode in a bath of acid (typically sulphuric or chronic), and an electric current is applied, causing the formation of a metal oxide layer. Anodising creates a smooth, highly resistant, visually appealing surface.
There are three main types of anodising, with the difference between them being the type and temperature of acid used and the duration of the process. These methods form layers with different characteristics. The types are Type I (Chromic acid), Type II (sulphuric acid), and Type III (sulphuric acid at a lower temperature and higher voltage).
Type II produces a layer thickness of 0. mm to 0. mm, while Type III produces a thickness of 0.025 mm to 0.05 mm. The Type II coating is also very receptive to dyes, providing numerous colour options. Anodising is typically used with aluminium but is also compatible with titanium, zinc, and magnesium.
Electroplating is an electrochemical process that deposits a thin layer of another metal on the surface of the sheet metal fabricated part. Common metals used in electroplating include gold, silver, and copper. In electroplating, The finished part is immersed in a solution containing plating metal ions. An electric current is applied, causing the ions to deposit onto the part's surface.
Electroplating improves corrosion resistance, improves surface finish, and creates a visually appealing surface. This process makes it possible to create a part with the properties of a particular metal without having to fabricate the entire part from the metal. For example, rather than creating a costly pure solid gold part, a sheet metal fabricator can create a part from steel and electroplate it with 70 to 90% less gold.
Annealing is the process of heating the part or workpiece to a specific temperature, followed by slow, controlled cooling. This process relieves internal stresses, improves ductility, and reduces hardness.
Normalising is similar to annealing but utilises air cooling at room temperature rather than the slow, controlled cooling utilised in annealing. This air cooling results in a more uniform grain structure and improved mechanical properties.
Also known as quenching, this process involves heating the workpiece to a high temperature and rapidly cooling it via immersion in a quenching medium such as oil, water, or air. As the name implies, hardening increases the workpiece's hardness and resistance to wear, abrasion, and deformation.
Tempering is typically performed after hardening to increase the toughness and reduce the brittleness of hardened parts. It involves reheating the workpiece to a specific temperature, holding that temperature, and then allowing it to cool on its own. The temperature determines how much of the hardness is reduced. Tempering creates a balance between hardness and toughness.
Quality control inspection is a critical aspect of sheet metal fabrication that ensures that the final products meet the required standards and specifications. Effective quality inspection involves three main stages: visual inspection, dimensional inspection, and nondestructive testing.
Visual inspection is the first line of defence in quality control. It involves thoroughly examining the sheet metal parts to identify any visible defects, such as surface imperfections, scratches, dents, or discolouration. Inspectors typically use magnifying glasses, mirrors, and machine learning cameras to aid in detecting defects, ensuring that each part meets visual quality standards before proceeding to further processing.
Dimensional inspection ensures that the fabricated parts meet the specified dimensions and tolerances. Inspectors use tools like callipers, micrometres, and high-precision lasers to measure the thickness, width, length, and numerous other dimensions of the sheet metal components. These precise measurements help identify any deviations from the design specifications, allowing for corrective actions to be taken before further processing.
Non-destructive testing (NDT) is crucial for detecting internal defects without damaging the parts. Ultrasonic and radiographic testing are two common testing methods.
Both ultrasonic and radiographic testing provide valuable information about the integrity of the sheet metal parts, ensuring their reliability and safety. These methods help manufacturers maintain high-quality standards and prevent the use of defective materials in final products.
Geomiq provides industry-leading post-production quality inspection involving these and more procedures. Every single order is subjected to thorough standard inspection for the utmost quality. You can also request advanced or custom inspection. Our numerous ISO certifications, including ISO : and ISO :, testify to our absolute commitment to superior quality standards. Visit our quality assurance page to learn more about Geomiq’s quality guarantee.
Sheet metal fabrication is compatible with various metals and their alloys. These materials are selected for different applications based on their properties, availability, and cost. The table below lists common sheet metal materials and their properties, common applications, and relative cost. Note that the table contains common sheet metals and is not exhaustive. In addition, each of the metals listed has alloys with varying properties.
Common sheet metals and their properties, applications, and relative cost
Geomiq offers these and more sheet metal material options. See our materials page to learn more. Not sure about the right material for your application? Contact us to discuss your project with our team of engineering professionals and select the best material for your application.
The applications of sheet metal fabrication are almost endless. This highly versatile manufacturing process is used in numerous industries to produce a wide range of products. Research and Markets estimates that the global Sheet Metal Fabrication Services market will surpass £15 billion by . From providing shipping containers that support global trade to building vehicles for outer space exploration, sheet metal fabrication is practically indispensable to civilisation.
Sheet metal fabrication is indispensable in the aerospace industry and is widely employed in aircraft and outer space applications. Numerous aerospace components and machines are manufactured from sheet metals. These include aircraft bodies, fuselages, skins, engine components, and spacecraft. A characteristic of sheet metal fabrication that is especially beneficial to the aerospace industry is its compatibility with various metals. This characteristic makes it possible to meet the various high demands of the industry. For example, sheet metal fabrication is compatible with aluminium for strong, lightweight aircraft parts and titanium to withstand the heat of spacecraft takeoff and the frigid temperatures of space. SpaceX’s Falcon 9 rocket is manufactured using sheet metal fabrication techniques from various aluminium and lithium alloys.
Sheet metal fabrication is the predominant manufacturing process in the automobile industry. Over 50% of car parts and components are manufactured from sheet metal, using a variety of sheet metal fabrication processes. Automobile parts such as body panels, quarter panels, floor pans, frame rails, inner fenders, brackets, mounting plates, bumpers, fluid tanks, casings, and more are all manufactured via sheet metal fabrication techniques, including cutting, stamping, rolling, drawing, welding, and numerous others.
This manufacturing process is fast, highly scalable, precise, and compatible with various metals, making it perfect for the automobile industry. Sheet metal fabrication extends beyond automobiles to other automotive and locomotive vehicles. Buses, lorries, trailers, rail cars, trains, and even tractors all predominantly feature sheet metal parts. In addition, maritime transportation is also facilitated via sheet metal fabrication. Marine vehicles, such as ships, submarines, and deep-sea trawlers, are all made from sheet metals.
The application of sheet metal fabrication in the construction industry is as vast and varying as the industry itself. Sheet metal is applied in building cladding, roofing sheets, doors and windows, plumbing and waste management, HVAC, power and gas supply, finishing, facades, railing, structural elements, gates, and decorative elements. Sheet metal fabrication’s vast construction applications are due to the durability, strength, high weather resistance, manufacturability, versatility, aesthetic qualities, and other beneficial properties of various sheet metals, including steel, aluminium, and copper.
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Featured content:One of countless examples of sheet metal fabrication in the construction industry is the Walt Disney concert hall in Los Angeles, USA. This building features an iconic stainless exterior comprising curves and complex shapes that the builders created using advanced sheet metal fabrication techniques.
This sheet metal application cuts across various industries. Many of the equipment and machinery used in production, agriculture, manufacturing, and oil and gas industries have sheet metal components, brackets, enclosures, and frames.
Sheet metal was one of the earliest forms of packaging and continues to be the go-to packaging material for numerous products. Sheet metal fabrication produces small to medium-sized containers for canned foods, beverages, paint, aerosols, gases, oils, and chemicals.
Manufacturers also produce large industrial-sized containers for storing various solids, liquids, and gases from sheet metal. This application cuts across various industries, including agriculture (silos), oil and gas (fuel storage tanks), shipping and logistics (Maritime containers), food and beverage production (production tanks), chemical processing (mixing and storage tanks), and many more.
Various Manufacturers utilise sheet metal fabrication to produce numerous consumer items. These items include the following:
The versatility of sheet metal fabrication makes it indispensable in the defence industry. This manufacturing method provides various metal options with the unique properties often required in defence applications. Examples include tungsten alloys for armoured tanks, copper and brass for ammunition, carbon steel for weapons, and titanium for military satellites.
Capability: Sheet metal fabrication can produce numerous complex cubic and parametric geometries, as well as various curves, shapes, and patterns. In addition, sheet metal manufacturers can use sheet metal fabrication techniques to produce extremely high-quality, durable parts and structures.
Versatility and availability of options: Sheet metal fabrication has various capabilities and characteristics that make it a highly versatile manufacturing process. This process can create standalone parts or whole assemblies, small or large structures, and one-off or large-scale productions. It is also compatible with numerous metals.
Another characteristic that adds to sheet metal fabrication’s versatility is the availability of processing options. At every stage of processing, there are several options to choose from, depending on the project. For example, cutting options include waterjet, plasma, and laser cutting. There are also various forming options, such as drawing, bending, spinning, etc. In addition, sheet metal fabrication is compatible with numerous finishing options.
Scalability: Most sheet metal fabrication processes can either be automated or process multiple parts simultaneously. This characteristic makes fabrication highly scalable and suitable for large production volumes. Most applications of sheet metal fabrication are carried out on an industrial scale using automated production lines.
Materials: Sheet metal fabrication is compatible with hundreds of pure metals, alloys, and super alloys. There are suitable sheet metals with unique properties for almost every possible application.
Accuracy: Incorporating advanced CNC machinery significantly improves the accuracy of precision sheet metal fabrication processes. Computers can control various aspects of fabrication, including cutting, forming, and bending. CAD also provides manufacturers with the ability to account for potential errors right from the design stage
Requires skills: Sheet metal fabrication requires highly skilled personnel from design to finishing. Most steps require meticulous execution. Fabricators must also follow numerous rules to ensure manufacturability, mitigate challenges during manufacturing, and achieve high-quality finished products. In addition, certain metal fabrication processes, such as welding and powder coating, are manual, increasing the possibility of error and the need for highly skilled workers.
Involves multiple operations: When comparing 3D printing and CNC machining vs sheet metal fabrication, the former typically involve one or two processes, while sheet metal fabrication often requires multiple steps, significantly increasing fabrication time, especially for one-off and manual productions.
Affects material properties: The deformation and temperature changes that workpieces undergo during fabrication may affect the internal structures of the metal. These changes can lead to stresses in the material and negatively impact its properties.
Generates waste: The sheet metal cutting process typically generates scrap from the trimmings and cutouts. However, this issue is mitigated by the fact that most sheet metal is recyclable.
Assembly - the action of putting together individual or partially assembled units to build a complete product. Base metal - the sheet of metal that is to be cut, bent, or punched.
Bending - the process of applying pressure to specific areas of the base sheet of metal to achieve a desired shape.
Blanking - the process of removing a piece in a desired shape from the base sheet of metal and discarding the remaining metal around it, like using a cookie cutter. Blanking typically occurs prior to bending but can happen while forming, depending on the machine.
CAD - computer-aided design; engineers use CAD software to design 2D and 3D models.
Coining - a forming process that uses pressure to mold a workpiece to the shape of a die.
Cutting - the use of blades, torches, or lasers to remove pieces of sheet metal.
Die - in soft tool, the lower part of a tool & die set that sits below the material; used to cut, shape, or form the material. In hard tool the die is the entire tool.
Embossing - a process that involves raising one side of the material while the other is depressed.
Forming - the process of cutting, punching, or bending sheet metal to create a desired shape.
Hard tooling - also known as sheet metal stamping, tools are made of more durable materials, making it ideal for large quantities of parts.
Hardware installation - the installation of hardware to allow for assembly includes nuts, studs, & standoffs.
Lancing - when a slice or slit is made in a piece of metal without causing separation from the main piece.
Laser cutting - an extremely precise cutting method that uses a concentrated beam of light. Also used by evil geniuses.
Machining/milling - the controlled removal of material using a cutting tool or lathe.
Nesting - strategically fitting multiple parts on a single sheet of metal to reduce waste; commonly arranged automatically by nesting software.
Plasma cutting - the use of concentrated ionized gas, or plasma, to melt away portions of sheet metal.
Powder coating - a dry powder surface coating applied to final metal pieces; when heated, it bonds with the metal to ensure a lasting finish and color.
Press brake - a machine that forms predetermined angles, or bends, by squeezing a sheet of metal between a matching punch and a die.
Punch - the upper part of a tool and die set that uses compression to cut, shape, or form the material.
Punch press - a machine that uses mechanical force and a die set to cut, pierce, or form a sheet of metal.
Riveting - the installation of a mechanical fastener, or rivet, through a hole in the material to hold two or more pieces of sheet metal together.
Set-up time - the time it takes to set up a machine, tool, or process. This time varies depending on the complexity of the part, machine, and process.
Shearing - a form of cutting in which downward force is applied to a piece of sheet metal, creating a clean break.
Soft tooling - the sheet metal fabrication processes that include laser cutting, turret punches, and press brake forming; a more cost-effective method than hard tooling because of its design & material flexibility
Stamping - accomplished using steel dies - progressive and stage - that are designed to stamp, bend, and form sheet metal.
Tooling - the equipment needed to carry out a particular function in the manufacturing process.
Tonnage - The amount of force applied by a press.
Turret - a type of punch press that uses turrets, or rotating tool holders, to punch sheet metal.
Welding - a process that involves melting or soldering two or more pieces of metal to join them together.
Workpiece - the material transformed into a finished part or component through manufacturing processes.
A press brake squeezes a sheet of metal between a punch and a die to bend it to predefined specifications. The material type, gauge, and geometry of the bend determine the tonnage, or force, needed to bend the metal. Standard punches and dies produce simple bends based on straightforward geometry, whereas custom punches and dies are created to implement more complex bends. Custom punches and dies do not lend themselves well to automated forming machines, and they may be better suited for automatic tool changers or robots.
Laser cutters use a laser to cut through sheet metal. The sheet is placed into the machine, and the laser cutting head is programmed to move along a desired cutting path. Laser cutting offers geometrical flexibility because the cut options are not limited to a standard tool. Some lasers have a stationary bed, but others move the sheet to its necessary position.
A turret press, also known as a turret punch, holds a variety of standard tools to punch shapes out of sheet metal. The sheet is laid flat and clamped into the turret. The machine is programmed to move the sheet metal across the machine bed and make a series of punches to achieve the desired part. Some machine models have a rotating turret, which holds a variety of tools and rotates to bring a specific tool into punching position. Others store their tools on a rail system, and the machine retrieves the needed tool.
Metal stamping is excellent for producing multiple, uniform metal parts at scale. Blank or coiled sheet metal is fed into a press, where it is shaped by a tool and die. Common operations are embossing, blanking, coining, punching, and flanging.
Sheet metal fabrication isn't just about cutting and bending. In many cases, multiple metal parts need to be combined. Welding and riveting are the two most common assembly options for sheet metal. The end use of the product should be considered when determining which method to use.
Welding is the most expensive joining method, but it is often the only viable process in areas that do not allow for overlap or assembly holes. It is also used in applications where strength and rigidity are critical. Because the heat produced by welding has a direct effect on metal quality, as a rule, heat should be minimized whenever possible
MIG - MIG stands for "metal inert gas" and is commonly referred to as wire-feed welding. MIG creates an electric arc between a piece of wire and the metal it touches, causing both to melt and join. It is best used on strong, thick materials that will not succumb to massive heat distortion.
TIG - TIG stands for "tungsten inert gas." This method is commonly used to weld stainless steel or aluminum. TIG welding is best used on thinner materials because it is easier to control the heat. It is more expensive than MIG welding because it is a slower, more labor-intensive process, but it is ideal for minimizing distortion.
Laser - Laser welding uses a laser beam to create a highly concentrated heat source to join pieces of metal together. This method allows an operator to target a precise area of a workpiece with a laser beam, which then heats, melts, and fuses the material. This process is frequently used in sheet metal fabrication when manufacturing a high volume of precision parts.
Spot - Two pieces of metal are placed under pressure between two copper alloy tips, which apply an electrical current, welding the pieces together. Welds are flush to the surface, and no fluxes or fillers are required, allowing for a clean appearance.
Robotic - Robotic welding is an automated process. Most robots are used for laser welding, resistance spot welding and arc welding. Human operators typically perform MIG and TIG welding; however, if a robot performs MIG or TIG welding, human assistance is required to prepare the welding materials.
Rivets are used to fasten two or more pieces of metal together using a manual or powered rivet tool. They are typically made of steel, stainless steel, or aluminum. Riveting has advantages over welding, including the ability to fasten dissimilar materials together or to fasten areas that are not accessible to other processes.
There are three basic types of rivets:
Solid Rivets - Solid rivets consist of a shaft and a head that becomes deformed during insertion. They are inserted using a special rivet machine or a standard hardware insertion machine. Solid rivets are very strong, but they require access to both sides of the sheet metal and an overlapping joint.
Semi-tubular Rivets - Semi-tubular rivets are similar to solid rivets; however, they have a partial hole at the tip. This small hole reduces the amount of force required to install the rivet. Like a solid rivet, access to both sides of the sheet metal and an overlapping joint are required.
Blind Rivets - Blind rivets are used when you can only see or access one side of the sheet metal. They have a cylindrical piece running through them called a mandrel. When the rivet gun pulls the mandrel, the rivet collapses on itself, securing the materials together.
Before the manufacturing process begins, engineers analyze the final product's function, aesthetic, and purpose. Mechanical engineers design the product and create the geometry of the part to determine the best tolerances and materials for production.
Manufacturing engineers determine the ideal machines, tools, and equipment for the production and assembly process. Designs are tested during the prototype phase to ensure the manufacturing process runs smoothly.
Design for manufacturability (DFM) involves reviewing product designs to ensure the final assemblies meet the desired outcome and can be manufactured in the most efficient way. Design for excellence (DFX) is an in-depth review of the entire product and its supply chain. The "X" is for excellence, which is a variable that can have many possible values, including assembly, cost, manufacturability, and time. DFX is an extension of DFM; it includes a broader view of the necessary components of manufacturing because manufacturability is only part of the picture.
Manufacturing experts must be well-versed in the production of a product, including engineering, machines, assembly, automation, quality, and supply chain, to provide the customer with valuable DFM and DFX. They review customer parts at the front end of the process to ensure the final assemblies meet the desired outcome. It is their responsibility to ensure parts are manufacturable, cost-conscious, and can seamlessly move into production, assembly, and testing.
Excessive Forming - Incorporating cuts or bends that do not have a functional purpose can create added costs. Excessive forming can also make the part impossible to bend.
Critical Dimensions - Some call-out information is not available in the CAD file and must be added to the drawings: datum planes, tolerances (block and critical), material type, finish requirements, hardware specifications, hole tapping, welding requirements, surface requirements, and edge requirements.
Standard Tolerances - Determining standard tolerances for sheet metal fabrication can be a complex process, particularly because the thickness of the raw material or sheet stock can vary. Manufacturing processes also impact tolerances because different machines have unique tolerance capabilities. Although machinery and tooling can repeat within .004", it is a mistake to simply engineer all mating parts to be within +/-.005" as it can lead to additional labor in sorting and inspection. Tolerances that are too tight result in higher costs and lower productivity. However, correct tolerances will still produce excellent fit and function, with the added benefit of manufacturing efficiency.
Hole Size - The size and shape of the punch and die tooling determine the size and shape of the hole placed in the sheet metal. The thickness of the stock material determines the minimum hole size.
For best results, the punched feature can be no less than the material being punched. The die tool is slightly larger than the punch to minimize tooling wear and reduce the pressure required to punch the hole. Generally speaking, 10% of the material thickness is used for most applications.
For example, if the material is .100" aluminum and the punch diameter is 1.000", the die diameter would be 1.010". The size of the hole on the punch side will be the same size as the punch tool. The size of the hole on the die side will be the same size as the die tool. Except for tooling wear, there is very little variation from one hole to the next. Generally speaking, +/-.003" is a reasonable and functional tolerance.
Hole to Hole - The accuracy of the distance from one hole to another primarily depends on the machinery used to process the sheet. Some equipment will hold better than +/-.005" with little difficulty. All holes and features punched through the sheet can cause stress. If the part has a closely spaced perforated pattern or has formed features such as dimples or counter sinks, the result can cause the sheet to warp and distort. This may lead to unwanted variation between holes or features. A greater tolerance should be applied to certain areas if this condition exists.
Hole to Edge - Part profiles are punched just like any other feature, except when using a machine with shearing capabilities. These dimensions should be considered the same as hole-to-hole. When punching close to an edge (less than double the material thickness), the edge can be pushed out by the stress of punching the metal. This edge movement can introduce variables in the accuracy of the hole location in relation to the edge. There are techniques to minimize this problem, but whenever possible, engineers should allow a +/-.010" hole-to-edge tolerance.
Hole to Bend - Several factors have been introduced leading up to the forming stage of the process. Press brakes will position and repeat within the +/- .002" range. Skilled brake operators can load the parts to form consistently from bend to bend. Nevertheless, consideration must be given to the natural variation in material thickness, (5% of nominal thickness), the +/-.005" from the turret press, the effects of cosmetic sanding, and the variation introduced by the press brake. A tolerance of +/-.010" hole-to-bend is functionally reasonable for most applications.
Bend to Bend - In addition to the variables that affect hole-to-bend tolerances, bend-to-bend tolerances are also impacted by introducing multiple material surfaces and thicknesses. Whenever possible, engineers should allow +/-.015" bend-to-bend. Increased tolerances need to be applied if going across multiple bends.
Both human labor and automation are used in sheet metal fabrication. Automating sheet metal fabrication operations can speed up production, provide better efficiencies, and improve safety conditions. Incorporating automation negates human error and fatigue; operators use it as a tool to enhance the manufacturing process.
A robotic operator is programmed to perform specific duties or to move a part or material according to set specifications. If a press brake has a robotic operator, for example, the robot is programmed to move sheet metal across the press brake to achieve each desired bend in the program.
Robotic operations improve productivity as well as quality. Robotic operators can perform with uniform precision every time, reducing potential ergonomic and safety hazards to human operators. For example, some programs require extremely repetitive motion that can injure a person over time. Robotic operators eliminate that risk.
Automated equipment or robots can quickly be reprogrammed to accommodate last-minute engineering changes, small batch runs, and line changeovers.
Robotic arms do not communicate with a machine and are programmed separately. They work well for pick-and-place operations, where they are programmed to move parts from one location to another. These robots are often paired with a human counterpart, making them collaborative.
Machine manufacturers are now incorporating automation and robots directly into their technology. These machines are built specifically to perform duties based on specific programming. A good example of this would be a panel bender, which has robotics built into the machine itself to move material through the forming process and into subsequent stages, storage, or racking. This machine is not built to be operated by a human and is fully autonomous by design.
Automatic tool changers (ATCs) remove and replace tools in a machine upon command. The manual set-up time for a press brake can take up to four hours depending on the number of bends, but ATCs take up to 30 minutes to set up, no matter how complex the program is. Whether working with press brakes or turrets, ATCs are accurate, fast, and reliable.
Automated sheet loading and unloading systems can be purchased for many machines, including turret and laser combos. This allows the fabrication process to continue seamlessly without needing to have an operator manually feed sheet metal onto the turret. This reduces potential ergonomic hazards and increases productivity.
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