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In the vast field of modern manufacturing,sheet metal Fabrication, as an important manufacturing process, plays an indispensable role. It is not only a technology or process, but also a bridge between design and manufacturing, cleverly transforming metal sheets into finished products of various shapes and sizes. This article will delve into the definition of sheet metal processing, the process flow, common techniques for sheet metal bending, the daily responsibilities and skills required ofsheet metalworkers, application areas and their importance in modern manufacturing. Help you not feel lost as a sheet metal fabricator?

What is sheet metal Fabrication?

Sheet metal fabricationis simply a process of processing metal sheets. It covers a series of processes from simple shearing and cutting to complex stamping, bending, welding, etc, aiming to shape metal sheets into specific shapes and sizes that meet customer needs and design requirements.

Advantages Of Sheet Metal Fabrication

Sheet metal fabrication includes a variety of techniques that offer many benefits. The final parts have uniform wall thickness with remarkable mechanical properties. The following are some of the major advantages of sheet metal fabrication

1.Accuracy and Efficiency

The accuracy and efficiency of sheet metal fabrication are top-notch. It is suitable for producing both prototypes and end-use parts. Furthermore, it is critical to understand that most sheet metal techniques are automated. The use of CAD software and CNC machining eliminates human errors. As a result, the final products usually have few or no deformations.

2.Versatility

The sheet metal fabrication process uses an array of techniques and tools. This makes it easy to choose the most suitable method for your project. Furthermore, metal parts fabrication does not limit the materials one can use. There are a thousand and more compatible metals. However, the application of the final part will influence the material you use.

3.High Capacity Production at Low Cost

With sheet metal fabrication, one can achieve a production capacity that is equal to the market demands. Though the initial cost may be high and the time of setting up may be long, it gets better when production begins. The more the parts produced, the more money one saves.

4.Manufacturing of Lightweight Components

Sheet metal fabrication produces lightweight yet durable parts. The excellent light-weight-to-strength ratio makes them useful in automotive and aerospace part manufacturing. Ultimately, it reduces manufacturing costs and improves fuel efficiency.

5.Custom-Built Designs

Sheet metal fabrication can be used to come up with innovative designs to build customized and unique parts. It is flexible and easily transforms metal sheets into personalized and aesthetically pleasing parts. The metal sheet fabricator can come up with innovative ideas and produce functional customized products.

What Types of Sheet Metal are Commonly Used?

Aluminum plate

aluminum sheet metalare widely used in the manufacturing industry due to their high strength-to-weight ratio and inherent corrosion resistance, catering to most applications. In aluminum plate manufacturing, usually Al1100 grade has strong corrosion resistance and easy formability. It has high thermal and electrical conductivity, making it suitable for use in transmission or grid lines. Grade 3003 is a medium strength alloy with good formability used in heat exchangers and cookware. Of the grades 5052 and 6061, the former is more common in sheet metal manufacturing due to its strength, formability, weldability and corrosion resistance. Grade 6061 is a structural alloy used in extrusion and high-strength applications such as truck and ship frames.

Galvanized sheet

The galvanized layer on the surface of thegalvanized sheet metalcan effectively prevent the steel sheet from rusting, extend its service life, retain the mechanical properties of the cold-rolled steel sheet, and have high strength. The surface is flat and smooth, suitable for occasions where appearance is required, the price is relatively moderate, and the price-performance ratio is high. Often used in the construction industry, automotive industry, household appliances, etc.

Copper/brass metal plate

Copper is an excellent conductor, and brass (copper-zinc alloy) also has good electrical and thermal conductivity, and is easy to cut, stamp and weld. Brass has better corrosion resistance than pure copper. Due to their different properties, copper and brass each have their own uses. Low zinc brass is easy to cold form, weld and braze. Copper sheet's high zinc content allows it to develop a layer of oxide or patina that will not continue to corrode and provide the desired appearance in applications such as construction and consumer products.

Titanium metal plate

Titanium metal sheets can be defined as thin, flat sheets of titanium, a metal known for its high strength-to-weight ratio and high corrosion resistance. These sheets are produced through processes such as hot rolling, cold rolling or powder metallurgy methods. Titanium metal sheets are widely used in the aerospace, automotive, medical and marine industries and their properties are highly appreciated. Due to its high strength, high temperature resistance and compatibility with the human body, it is used in the production of products such as aircraft frames, engine parts, human implants and marine products.

How is the sheet metal Fabrication process performed?

1.design

The design phase is where the foundation for the project is laid. Designers typically create an initial sketch or 2D/3D model of a product, which can be done using computer-aided design (CAD) software or by hand. Listing important factors such as the intended use of the product, required dimensions and tolerances, and any specific materials or finishes required before production begins.​

2.cutting

Laser cutting is often the first step in the manufacturing process. Laser cutting is one of the most precise methods of cutting sheet metal because of the laser's ability to follow the programmed design and cut the material accurately.​

3.bending

Use equipment such as a bending machine orCNC bending machineto bend the cut sheet metal parts. According to the design requirements, select the appropriate bending mold and bending angle to ensure that the bending area is smooth and crack-free. For parts that require local bending, such as corners or specially shaped areas, fine operations are required to ensure bending accuracy and appearance quality.

4.forming

The forming process bends or deforms materials into the desired shape. Unlike cutting (reducing material), shaping actually reshapes material without reducing its mass.

5.welding

There are a variety of welding techniques available for working with sheet metal, including MIG welding, TIG welding, robotic MIG welding, and spot welding.​

Metal Inert Gas (MIG) Welding: This is a typically fast welding option that is better suited for thicker materials.

Tungsten Inert Gas (TIG) Welding: Provides better control and precision than MIG. Best for thinner materials. You may also see it referred to as gas tungsten arc welding (GTAW).

Robotic MIG Welding: This is an automated version of more traditional MIG welding.

Spot Welding: This is the follow-up process to the resistance welding process.

6.finishing

Finishing is the final step in preparing a metal product and makes it more resistant to corrosion, adding another layer of durability. It also helps make the surface look more aesthetically pleasing. Common jobs include surface treatment, polishing and powder coating with optional colors, anodizing, passivation and more.

7.test

Conduct comprehensive quality inspections on processed sheet metal products, including dimensional measurement, appearance inspection, performance testing and other aspects. Ensure products meet design requirements and quality standards.

8.Package

Products that have been processed and inspected must be properly packaged to prevent damage during transportation and storage. During the packaging process, attention should be paid to product fixation and protection measures to ensure that the product reaches the customer safely.

What are the Techniques Used in Bending Sheet Metal?

Commonsheet metal bendingtechnologies mainly include:

1.Manual folding

If you don't have a press brake, hand-bending sheet metal is also an option. First, you need to calculate the bending tolerance of the sheet based on the type of metal used. Next, mark the bend lines with a marker and cut the sheet to size. Place the board securely in the vise clamps, using the block of wood as a reference for the shape or angle into which to bend the board. Next, tap the sheet lightly with a wooden mallet until the metal deforms. This method is only recommended for sheets up to 2 mm thick, as thicker sheets may break. While manualbending sheet metalis a simple and quick method, it does not guarantee the level of quality and precision that a press brake can provide. For thicker sheets or more complex bends, it is recommended to use a bending machine to avoid sheet breakage.

2.bending machine

Press brakes are essential for fabricating structures involving sheet metal fabrication. Itsheet metal bend by punching them into the correct shape on a mold. The machine can bend panels up to 20 mm thick. There are two types of bending machines: mechanical bending machines and hydraulic bending machines. Using a press brake, you can make V- or U-shaped bends. A V-bend (V-bend) is formed when metal is stamped into the shape of a die. This bending can only be done with sheets that are not thicker than 2 mm. Air bending can also be done using a press brake, where the punch only presses the sheet to the desired angle rather than completely into the die. The bending machine is a multifunctional tool that can perform various bends on sheets of different thicknesses.

3.Laser bending

Laser bending is a relatively new technology that relies on the precision of the laser beam to produce high-quality bends. The laser bending machine combines the advantages of laser cutting and bending machines. First, a laser is used to cut the metal sheet into the desired shape and size. Next, the laser is still used to heat the area of ​​the metal sheet to be bent, making the metal more ductile, making it easier to bend the metal sheet. After the metal sheet is heated, a conventional press brake performs the bending. Thisbend sheet metaltechnology offers several advantages, including the ability to bend quickly and accurately and to bend very thick sheets. It can also bend at very large angles without the risk of deformation or cracking of the sheet.

What Does a Sheet Metal Fabricator Do?

Processing and production:Process and produce sheet metal parts according to design drawings, process standards and production plans. Use various sheet metal processing equipment, such as shears, bending machines, punches, laser cutting machines, etc., to perform cutting, bending, stamping and other process operations.

Quality control:Conduct quality inspections on sheet metal parts during processing to ensure that products meet design requirements and quality standards. Participate in product acceptance work to ensure that the final product meets the quality requirements of customers or the company.

Production records and equipment maintenance:Keep production records, including processing processes, equipment usage, material consumption, etc., to facilitate follow-up tracking and improvement. Responsible for the daily care and maintenance of processing equipment to ensure that the equipment is in good condition and improve production efficiency.

Safety and environmental protection:Strictly abide by safe operating procedures and wear protective equipment to ensure safety during work. Dispose of waste and scraps generated during processing in a timely manner to keep the workplace clean and environmentally friendly.

Communication and collaboration:Maintain communication with design, purchasing, sales and other departments to understand product needs and progress to ensure the smooth progress of production tasks. Collaborate with team members to complete production tasks and improve the overall effectiveness of the team.

Key Takeaways on Choosing Sheet Metal Gauge Thickness

Understanding sheet metal gauge thickness is key for any project. It’s not just about picking a number. You need to consider several factors to make sure your parts fit and perform as expected.

KeyTakeaways	illustration
Gauge System	Smaller numbers mean thicker metal. But gauges vary by material. Always check a gauge chart to know the exact thickness.
Project Needs	Think about strength, weight, and corrosion resistance. Thicker gauges offer more strength but can add weight. For outdoor projects, choose a gauge that complements the metal’s natural resistance.
Cost vs. Benefit	Thicker sheets often cost more. Balance material costs with your project requirements. Sometimes, a slight reduction in thickness can save money without compromising quality.
Material Availability	Always check what your manufacturer has in stock. Designing for unavailable gauges can cause delays and extra costs. Open communication with your manufacturer can help streamline your project.

Choosing the right thickness requires making an informed decision. Consider strength, weight, corrosion resistance, cost and availability. Check with your manufacturer to make sure the material you are using is best suited for your needs. Some commonsheet metal gauge chart:

What are the application fields of sheet metal processing?

1.Electronic and electrical industry: used to make housings and components of electronic products such as chassis, cabinets, and heat sinks.

2.Automotive industry: used to make body panels, chassis parts, fuel tanks and other auto parts.

3.Machinery manufacturing industry: used to make protective covers, brackets, shells and other components for various mechanical equipment.

4.Construction industry: used to make stair handrails, door and window frames, ceilings and other architectural decorations and components.

5.Household appliance industry: used to make shells and internal brackets for refrigerators, washing machines, air conditioners and other household appliances.

How to choose the most economical sheet metal Fabrication solution？

Define the needs and objectives

• Product requirements:First, specify the product size, shape, accuracy and performance requirements, as well as the expected production volume and delivery time.
• Cost target:Set a clear cost budget and cost control target.

Evaluate the raw material costs

• Material selection:select the most suitable sheet metal materials, such as aluminum plate, stainless steel, and consider the cost, performance and availability of the materials.
• Material utilization rate:By optimizing product design, improve material utilization rate, reduce waste generation, and reduce material cost.

Consider processing costs

• Processing method:according to the product requirements to choose the appropriate processing method, such as bending, curling, stamping, punching and cutting, etc. Consider processing efficiency, depreciation of equipment, and labor costs.
• Mold cost:for the required mold processing methods, such as stamping, to evaluate the cost and life of the mold, as well as the cost of mold replacement and maintenance.
• Process optimization:reduce the processing cost by reducing the use of processing steps and reducing auxiliary materials.

Evaluate production costs

• Equipment cost:consider the cost of purchase, depreciation and maintenance of the required equipment.
• Labor costs:to assess the labor needs in the production process, including the direct and indirect labor costs.
• Production efficiency:improve production efficiency, reduce production time and cost. Consider the application of automation and intelligent production technologies.

Through the above methods, we can choose out of the most economical sheet metal manufacturing scheme, and ensure that the cost control and benefit maximization in the production process.

longsheng: Your trustworthy sheet metal fabricators

At longsheng, we are not only proficient in various skills mentioned above, but we have a professional technical team that can provide leading sheet metal manufacturing services to manufacture high-quality parts for you at very competitive prices. As an ISO 9001:2015 certified company, we focus on the construction of quality management systems to provide customers with reliable services.
Our expert team has experience performing DfM (Design for Manufacturability) analysis to improve your design. We are not only a manufacturer but also a partner, committed to providing our customers with full support and expert advice to ensure designs reduce manufacturing costs while still meeting high quality standards.
If you have a design model that needs to be manufactured, please upload it to us immediately and we will provide you with a quote immediately. Choosing longsheng means choosing asheet metal fabricatorswith high quality, high technical level and high cost performance. Let us work together to create excellent parts for your project and achieve greater success.

FAQs

1.What does a sheet metal fabricator do?

The daily responsibilities of sheet metal workers involve processing and production, quality control, production records and equipment maintenance, safety and environmental protection, communication and collaboration, etc.

2.What is the metal fabrication process?

First, create an initial sketch or 2D/3D model of the product, use cutting technology to cut the metal plate, and then use equipment such as a bending machine, CNC bending machine, etc. to bend the cut sheet metal parts. Bend or deform the material into the required shape according to the drawings, then weld the metal plates, and finally sort, test and package the metal products.

3.Is welding the same as sheet metal fabrication?

Welding and sheet metal processing are two different metal processing processes. There are obvious differences between welding and sheet metal processing in terms of definition, operation method, scope of application, processing effects and advantages, and cost. In practical applications, appropriate processing methods should be selected based on specific needs and product characteristics.

4.What is the difference between casting and fabrication of metal?

There are significant differences between metal casting and manufacturing in many aspects. These differences are mainly reflected in the definition, process, scope of application, quality requirements and operational details. Which process to choose depends on factors such as the specific needs of the product, cost considerations, and production conditions.

Summary

As an important metal processing method, sheet metal processing plays an irreplaceable role in modern industrial production. With the continuous advancement of science and technology and the continuous development of the market, sheet metal processing technology will continue to innovate and improve, providing more high-quality and efficient metal products for all walks of life.

Disclaimer

The content on this page is for reference only. Longsheng does not make any express or implied representation or warranty as to the accuracy, completeness or validity of the information. No performance parameters, geometric tolerances, specific design features, material quality and type or workmanship should be inferred as to what a third party supplier or manufacturer will deliver through the Longsheng Network. It is the responsibility of the buyer seeking a quote for parts to determine the specific requirements for those parts.Please contact us for more information.

Longsheng Team

This article was written by multiple Longsheng contributors. Longsheng is a leading resource in the manufacturing sector, withCNC machining, sheet metal fabrication,3D printing,injection molding,metal stamping, and more.