Metal Fabrication

Our Metal Fabrication Processes

Metal fabrication is an essential manufacturing process and The Federal Group has the capability of shaping metal in a number of ways using state of the art equipment. Below are some of the common metal fabrication processes that we specialize in.

Stamping

Stamping is when metal sheets are hit with a die at high pressure to create a specific shape.  Punching is a form of stamping that uses a press to force a die into the metal. This can create a hole, many holes, embossing, or other shapes in the metal. This can be performed on sheet metal and rolled materials.

Hot extrusion

Hot extrusion is the process of forcing metal through a die to create a cross-sectional profile. This extrusion process is done at high temperatures.  This keeps the materials from work hardening and makes it easier to push the material through the die.

Welding

Above: A water fountain fabricated by TFG USA.

Welding is when two pieces of metal are joined together using fusion. Different types of welding include oxyacetylene, tungsten inert gas welding, shield metal arc, and gas metal arc welding.

Welding is done at a high temperature and uses a filler metal material. Welding can involve a chemical flame, electricity, pressure, or lasers to achieve the heater needed to join the metals.

Folding or Bending

Image above: A fireplace frame manufactured by cutting and bending sheet metal.

Folding or bending involves force being applied to the metal material to alter its shape. The metal is bent manually by hammer or hydraulically with press brakes. This metal fabrication process is typically done with flat sheet metal.

Laser cutting

Laser cutting uses programmable laser cutters to cut most metals, however, the thickness of the metal that can be cut is limited. Depending on the Metal chosen the thickness varies from ¼” to 1”. This process can also be expensive due to the amount of electricity needed.

Water-jetting

Water-jetting or waterjet cutting is an alternative to laser cutting. It uses a thin jet of water being shot out at nearly 90,000 PSI.  Water-jetting is more effective at cutting thick metals than lasers.

Metal Spinning or Spin Forming

Metal spinning or spin forming is a process that shapes metal through spinning. This process starts with a sheet of metal in disc form or a tube of metal.

The material is then shaped by a CNC lathe rotating at high speed. High pressure is exerted on the material to form it into a specific shape.

Casting

Image above: Automotive thermostat housing manufactured by sand casting.

Casting is another popular process used for metal fabrication. Metal casting involves filling a hollowed mold of the desired shape with a molten metal material that then solidifies.  There are a number of different methods for casting including sand casting, investment casting, and die casting to name a few.

Finishing

Finishing is the final step in the metal fabrication process. Once a metal piece has been completed, it can then be sandblasted, painted, powder-coated or anodized.

Explore the Advantages of Our Metal Fabrication Process

At The Federal Group USA, we produce a wide array of products and assemblies. Customers continue to rely on our fabrication capabilities, thanks to these advantages:

• In-depth product analysis
• Increased product performance
• Shorter product development cycles
• Wide range of capabilities
• Decreased manufacturing costs
• Compliance with industry standards
• Quality control and inspection services

We provide full-service metal fabrication services, working with you from the design phase to manufacturing. Our experts work closely to assist every step of the process. Allow us to analyze and review your designs in order to achieve increased quality and lower costs.

Working with a team of domestic and global partners, our dedicated staff can address any manufacturing challenges.

We have supply chain operations in major regions around the world along with the latest fabrication equipment and knowledge. You can depend on TFG USA for all your industrial component parts and assemblies.

Improve the Performance of Your Product

While we shape metal to your specifications, we also aim to improve the performance of your products. We help mitigate risks, anticipate challenges, and deliver quality parts.

Customized fabrication tends to increase the service life of products. When metal parts are customized for your specific application, they are fabricated to handle the stresses of your project.

We help select the right materials and thoroughly analyze your designs and drawings to improve the overall performance.

Get Your Products to Market More Quickly

You also benefit from our efficient manufacturing processes. We have a large operation with facilities and supply partners across the world. We work quickly to meet your timetable.

We also increase efficiency during the design process. Our goal is to reduce fabrication costs and increase the speed of the fabrication process.

Stop worrying about deadlines. Work with experienced engineers and fabricators to source your original parts quickly.

Wide Range of Metal Fabrication Materials

No matter the material, we have you covered. Common types of metal include:

• Aluminum fabrication
• Brass
• Bronze
• Carbon steel
• Copper
• Iron
• Stainless steel
• Steel
• Titanium

Along with fast results, we have the capability to work with a variety of metals and raw materials including sheet metal and plate metal, liquid metal, metal rods, metal bars, and more.

We offer MIG or TIG welding for any weldable alloy. You can also rely on us for dependable folding, bending, cutting, spinning, and finishing.

With expert finishing and assembly, you can ensure that your parts match your exact specifications. Our finishing process includes painting, powder coating, galvanizing, anodizing, CNC machining, and dozens of other options.

Boost Profits with Lower Manufacturing Costs

Outsourcing your metal fabrication services helps lower the cost of your manufacturing processes. We work with you to reduce costs, which results in more profits.

During the design process, our engineers can help uncover weaknesses without the need for expensive prototypes. We help cut costs while delivering superior products.

Meet International Standards

Customized fabricated parts often need to comply with specific industry standards, which can vary across regions. To meet the local or international standards, work with a team that has global experience and resources. We adhere to all international standards for the manufacturing of all types of parts, components, and assemblies.

Work With Experienced Metal Fabricators

We are a U.S.-based metal fabrication shop with a global reach. TFG USA is headquartered in Ferndale, Michigan. Launched in 1980, we have a long track record of providing customers with reliable fabrication solutions.

We only use the best metal fabrication tools, equipment, and materials. Our facilities are equipped with the latest machines to stamp, fold, or weld any part.

We have worked with customers in a wide range of industries and industrial products from commercial metal fabrication to structural metal fabrication. Below is a list of some of the industries that we commonly produce metal fabrication for:

• Agriculture
• Aircraft
• Automobile
• Construction
• Consumer products
• Electronics
• Heavy truck and recreational vehicles
• Hobby and toy
• Marine
• Medical
• Off-highway and railway
• Telecommunications

Our metal fabrication capabilities also cover all types of applications and manufacturing needs. You can rely on us for short-run or high-volume fabrication and manufacturing. We also provide world-class precision fabrication and quality assurance.

Whether you need parts created for aerospace and defense applications, metal parts fabrication for heavy trucks, metal fabrication for medical equipment or anything else, we’ll be able to provide you with high-quality, reliable service.

With global connections, resources, and high-quality facilities, we are your source for reliable parts. Our machine shops are equipped to bend, cut, form, weld, and finish the highest quality metal products.

When it comes to working with a metal fabrication shop, make sure to partner with a team that works with you to develop precision custom metal products. Contact The Federal Group USA today to discuss your project.

Pictured above: An industrial fan assembly fabricated by TFG USA.

The Federal Group’s Metal Fabrication Capabilities

At The Federal Group USA, we produce a diverse range of products and assemblies via metal fabrication including automotive, motorcycle, electrical, industrial, medical, structural metal parts, information technology, commercial metal products, mining, signage, transportation, and construction, just to name a few.

Whatever your project, from sturdy steel frames to machine components, our engineers will find a way to make your metal fabrication job a reality. We will help you throughout the entire manufacturing process from the material handling to the planning stages and all the way to a final custom metal fabricated product.

Looking for an experienced metal fabricator? The Federal Group USA has been in the metal fabrication industry for 40+ years and we are eager to learn more about your next project. Contact us today for a free quote.