What Is Sheet Metal Fabrication?

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 the right choice still exists, depending on the costs and needs.

Types of Metal Fabrication Processes
The journey from sheet metal to metal products starts with 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 sheets. 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 you to rather go with laser cutting services.

Mechanical Cutting
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
Punching is another way of 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 in the need for a separate tool for different cuts.

Bending
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.

Powder coated sprockets

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.

Advantages of Sheet Metal
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 of 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.

Sheet Metal Applications
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 lar.

Partnering for Success

Navigating the complexities of modern precision sheet metal and stamping demands more than just machines; it requires a partner with deep engineering knowledge, stringent quality control (like GD&T adherence), and a commitment to innovation in materials and processes. Choosing the right fabricator impacts your product’s performance, time-to-market, and bottom line.

Ready to see how precision engineering can elevate your next project? Explore our capabilities in complex sheet metal fabrication, precision stamping, and custom tooling design at: www.vanmodel-sheetmetal.com