Sheet metal fabrication is the process of forming parts from a metal sheet by applying different manufacturing techniques. Our shop utilizes state-of-the-art equipment and skilled technicians to deliver high-quality custom sheet metal components. This article will provide an in-depth overview of our end-to-end sheet metal fabrication process.

Materials Used

We work with a wide range of sheet metal materials including:

Steel

• Mild steel
• Stainless steel
• Galvanized steel
• Tool steel

Steel offers high strength and durability. We commonly use mild steel for structural components and enclosures. Stainless steel is chosen for its corrosion resistance while galvanized steel is used for applications requiring rust protection.

Aluminum

• 1100 Aluminum
• 3003 Aluminum
• 5052 Aluminum
• 6061 Aluminum

Aluminum is lighter than steel and provides good corrosion resistance. We frequently use 6061 aluminum for structural parts that need to be lightweight. 3003 aluminum is suitable for chemical storage while 5052 aluminum offers excellent rigidity.

Other Metals

• Copper
• Brass
• Titanium

These metals provide unique benefits like electrical conductivity, corrosion resistance, high strength, etc. We select the optimum metal for each application based on the requirements.

Design and Engineering

The first step of our sheet metal fabrication process is design and engineering. Our team of experienced engineers work closely with customers to develop the part design from concept to finished drawings.

Specification Gathering

We start by understanding the application, operating conditions, size constraints, performance requirements and any other specifications for the sheet metal component.

Conceptual Design

With the design goals established, our engineers create conceptual sketches and basic models of the part. We consider manufacturability while optimizing the design for functionality.

Detailed Design

Next, the concept moves to the detailed design phase. Precise 3D CAD models and drawings are created showing all features, tolerances, and dimensions. Our engineers perform simulation analysis to validate the design.

Prototyping

We produce prototypes to test fit and function before full production. Prototypes provide the opportunity to fine-tune the design if needed.

Our comprehensive design and engineering expertise helps deliver parts that meet the exact standards. Close collaboration with customers at every stage ensures the finished product matches the requirements.

Raw Material Procurement

Once the design is finalized, we procure the required sheet metal raw material. Our quality control team inspects all incoming metal sheets to ensure they meet specifications before releasing to the shop floor. We maintain a large in-house inventory of standard sheet metal materials for faster lead times. For special alloys and sizes, we source metals from certified mills per the order requirements.

Sheet Metal Materials We Stock:

• Hot rolled steel
• Cold rolled steel
• Galvanized steel
• Stainless steel grades 304 & 316
• Aluminum grades 6061, 3003 & 2024
• Brass alloys 260, 353, & 360

Fabrication Methods

Our fabrication shop is equipped with advanced CNC machinery to produce parts with precision and efficiency. Here are the primary techniques we use for sheet metal manufacturing:

Shearing

Shearing uses a guillotine-style machine to shear sheet metal into straight-line cuts. We have large capacity shears to cut thick steel sheets up to 1??? clean and straight. Shearing is an efficient method for slicing large sheet metal stock into smaller blanks in preparation for further processes.

Punching

Punching uses a hydraulic punch press fit with hardened tool steel dies to punch holes into sheet metal. We have programmable punch presses that can punch holes of any shape and size with extreme consistency. Some applications require hundreds of holes, which is easy to achieve with our automated punching equipment.

Forming

Forming shapes the sheet metal into 3D forms by applying pressure. We utilize press brakes, stamping presses, and CNC bending machines to form components with complex geometries. Custom multi-stage progressive dies are engineered for high-volume production parts. For heavy duty forming needs, we have 400-ton stamping presses.

Welding

We join sheet metal parts together through various welding techniques. Our skilled team performs MIG, TIG, spot, and laser welding to fuse metals per the design needs. Robotic welders allow for repeatable and consistent welds. We conduct testing to ensure weld integrity on all components.

Hardware Insertion

Where needed, we mechanically insert nuts, bolts, and other hardware into the sheet metal parts. Automated equipment allows high-speed insertion of thousands of fasteners. This eliminates the need for secondary operations to attach hardware.

Deburring

The edges of sheet metal parts are deburred to remove sharp edges and improve safety. We use wet deburring equipment for high-production deburring. For prototypes and low-volume parts, technicians hand finish edges to ensure smoothness.

Bending & Folding

Bending forms sheet metal at straight axis lines while folding creates sharper formed corners and bends. Our press brakes have the tonnage capacity and precision necessary to make accurate folds and complex bends per the drawings.

Cutting & Machining

For applications requiring high precision, we use CNC machining centers to cut, drill, and shape sheet metal. LATHEs and mills cut sheet metal stock into extremely tight tolerances. Multi-axis laser and waterjet cutters also enable precise hole shapes and patterns.

Our comprehensive sheet metal capabilities allow us to produce parts from simple pieces to complex assemblies manufactured completely in-house.

Secondary Processing

After initial fabrication, parts undergo additional secondary processing:

Degreasing & Cleaning

All sheet metal parts are thoroughly cleaned to remove oils, dirt, and debris before moving to finishing or assembly. We use aqueous washing systems for environmentally safe cleaning.

Finishing

Our finishing department applies various coatings to enhance durability and appearance. Common finishes include powder coating, wet spray painting, plating, anodizing, etc. We operate fully equipped paint booths and plating lines in-house.

Quality Inspection

Every part goes through inspection points throughout fabrication. We thoroughly examine dimensions, fit, and cosmetics using calibrated measurement tools. Parts are inspected again before final shipment.

Assembly

Where needed, we assemble sheet metal sub-components into larger assemblies using mechanical fasteners, welding, and adhesives. Our programmed torque control tools ensure proper tightening.

Packaging & Shipping

Finished parts are carefully packed to prevent damage during transit. We package small parts in custom crates while large components are secured to pallets. Our logistics team coordinates on-time delivery.

Why Choose Us For Your Sheet Metal Project?

When you choose us for your sheet metal fabrication needs, you get:

• One-Stop Solution: With comprehensive in-house capabilities, we can take projects from design through delivery without relying on multiple shops.
• Advanced Equipment: Our large-capacity CNC machinery and CAD/CAM systems enable fast turnaround of large and complex components.
• Skilled Craftsmanship: Our experienced team has the technical know-how to fabricate challenging geometries to meet your needs.
• Stringent Quality Control: We adhere to strict protocols and conduct inspection at each step to deliver defect-free products.
• Custom or Production: Our facilities can handle low to high volumes making us ideal for prototypes or production runs.
• Customer Focus: As a job shop, we are flexible and focus on providing tailored solutions based on your requirements.

Get in touch with our engineering team to discuss your next sheet metal project!

Frequently Asked Questions

What sheet metal materials do you work with?

We work with all common sheet metal materials including various grades of steel, aluminum, stainless steel, copper alloys, and more. We select the optimum metal for each application based on the design requirements.

What sheet metal gauges (thicknesses) can you fabricate?

Our shop can handle sheet metal ranging from thin gauge items like brackets and panels down to 1/16??? up to thick plate up to 1??? thick for large structural components. Our wide capacity range allows us to fabricate parts of all sizes.

What sheet metal fabrication services do you offer?

We provide end-to-end sheet metal services including punching, shearing, bending, forming, machining, welding, finishing, powder coating, assembly, and hardware insertion. This enables us to manufacture complete assemblies in sheet metal.

Can you work from customer drawings?

Absolutely. We can fabricate parts from your 2D drawings or 3D CAD models. For custom designs without existing prints, our engineering team can help design the part for optimal manufacturability.

What industries do you serve with your sheet metal fabrication?

Our parts are used in diverse industries like aerospace, agriculture, automotive, electronics, HVAC, medical, transportation, and many others. We have experience working with companies of all sizes from all sectors.