Sheet metal fabrication is a key technology employed in the manufacturing processes of different industries. It involves preparing sheet metal using a range of techniques such as bending, welding and forming. Due to its versatility and durability, it is widely used to develop stands, enclosures, and other components.In order to produce the finished product, various processes are used depending on the specific project needs. The following list provides insight into common sheet metal fabrication methods to better understand the process.Materials of Sheet Metal Depending on fabrication and application requirements, the composition of sheet metal may vary. The most widely used multifunctional metals in various applications are steel and aluminum. ● Aluminum Aluminum, while weaker than steel, is still a good choice because of its lighter weight. Its durability makes it suitable for refrigeration, roofing, aerospace engineering and more, especially in cold climates. ● Steel Durable and flexible, steel comes in many forms: stainless steel, galvanized steel, carbon steel, and black iron steel. ● Copper In addition to its attractive appearance, copper is also highly conductive and corrosion-resistant, making it a versatile material for a variety of applications. ● Brass With its excellent acoustic properties and corrosion resistance, brass has become the material of choice in the manufacture of firefighting equipment, musical instruments and a wide variety of accessories and components. Sheet metal finishing Learn about the impact of surface treatments on sheet metal durability and performance. For optimum corrosion resistance and to maintain their integrity, various materials must undergo specific surface treatments. Visit our finishes page to learn more about grits, colors and common finishes. Like surface treatments in other metal fabrications, sheet metal comes in different finishes. The type of surface treatment to use depends on the unique needs of the part and the properties of the material chosen. To compare various sheet metal finishes, view the list below. If you are interested in detailed information on each finish such as roughness, color and grit, along with accompanying images, please go to the Surface Finishing page. Comparison of sheet metal finishing ● Bead blasting Description: A consistent matte or satin surface finish can be achieved by blasting abrasives, such as glass beads, onto the part at high velocity. Application: This technique is mainly used for aesthetic reasons and to prepare the surface for coating. It is available in a variety of coarse grains, which indicate the particle size of the bombardment surface. Anodizing can also be combined for added versatility. ● Powder coating Description: A protective polymer layer is applied to the surface of the part using powder coating. Application: Sandblasting can be used in conjunction with metal for decorative and protective purposes. ● Anodizing Description: The process electrochemically forms a durable oxide coating on a variety of materials, most commonly aluminum. Application:This technique can enhance the corrosion resistance and appearance of materials such as aluminum, titanium, zinc, and magnesium. ● Chromate conversion coating Description: The method of immersing materials such as aluminum, titanium, zinc and magnesium in a chemical bath creates a protective coating and improves its appearance, often called an alodine or chemical film. Application:Functional use is recommended over decorative applications for best results. ● Brushing Description: A satin finish can be achieved on metal surfaces by brushing the material with grit in a single direction. Application: When it comes to customer-facing parts, brushing is often used for aesthetic purposes. It effectively hides processing defects. ● Brushing + electropolishing Description:Metal parts are brushed for aesthetic purposes and then electropolished using an electrochemical process to passivate, deburr and polish. Application: Ideal for achieving microscopic smoothness, brushing works well on most metals, though it's commonly used on stainless steel.● Sheet metal can be bent into the desired shape by using a bending machine. ● Hydraulic presses and dies are used to stamp and form the metal inside the machine. ● This is a common method used in electronics enclosure manufacturing.● In a stamping press, a sheet metal blank is machined into various shapes using dies and tools. ● This approach is flexible and allows complex shapes to be constructed through repeated punching. ● Flanging, punching, embossing and stamping are standard methods. ● Metal brackets and automotive body parts are the most common applications.● Wall Thickness The process of sheet metal fabrication involves shaping different components from a single metal sheet, and a uniform thickness is essential for maintaining their geometry. Generally, the thickness of sheet metal parts can range between 0.9 mm to 20 mm. Nevertheless, various custom fabrication techniques deal better with specific thickness levels. For example, laser cutting caters to metal sheets between 0.5 mm to 10 mm, while sheet metal bending can manipulate metal sheets between 0.5 mm to 6 mm. ● Holes and Slot Orientation Hole and slot dimensions play a critical role when designing parts in custom sheet metal fabrication. Ideally, the diameter of these features should match the thickness of the material. Proper spacing between the holes is also important, they must be kept a safe distance from the edge of the material to avoid any potential weak spots. ● Bend Allowance and Deduction To obtain a flat pattern in custom sheet metal fabrication, the part's measurements must be adjusted for bend allowance (additional material length) and bend deduction (removal of excess material from flange length). This ensures a balanced and accurate design. ● Bend Radii In custom sheet metal fabrication, maintaining a consistent bend radius is critical to preventing defects and distortion in the final product. It also improves cost-effectiveness and product positioning, making it an important aspect of sheet metal engineering.● Laser technology is widely used by different industries to cut materials such as metals and plastics. ● The precise heat beam generated by the laser vaporizes the material and leaves a clean cut. ● Now, this technology is in high demand in the manufacturing, automotive, aerospace and even hobbyist markets.● Sheet metal fabrication is the process of forming metal into shape using specialized dies and presses. ● Used when punching cannot reach the desired depth of the part. ● The technology can be used to produce a wide variety of products, from medical devices to automotive gas tanks and kitchen sinks.Welding is an important part of sheet metal engineering. This is the process of heating pieces of metal until they melt, then using a flashlight to fuse them together. Soldering helps create complex designs and ensures that the final product is strong and durable.