Custom Metal Fabrication Services

Wide Range of Metal Fabrication Materials

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

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

Along with offering accelerated production, we can work with various metals and raw materials, including sheet metal, plate metal, liquid metal, metal rods, metal bars, and more.

Boost Profits with Lower Manufacturing Costs

Outsourcing your metal manufacturing services to The Federal Group helps lower manufacturing costs to increase profitability. Our advanced manufacturing techniques streamline production and reduce waste, and by putting our extensive experience and global supply chain knowledge to use, we boost your profits even further. 

We start with an in-depth analysis of your design, working to optimize waste reduction and eliminate inefficiencies throughout the production cycle. Then, we use our industry knowledge to find reliable metal fabrication suppliers offering competitive, high-quality materials. 

Meet International Standards

Customized fabricated parts often need to comply with specific industry standards, which can vary by region and application. The experienced team at TFG USA has the global experience and resources necessary to ensure your components meet all applicable local and international standards, including ISO, ASTM, and ASME requirements.

Improve the Performance of Your Product

At The Federal Group, we do more than shape metal–we offer custom metal fabrication services that improve the performance of your products. From start to finish, our experienced team works closely with you to deliver quality parts by helping you identify potential challenges and mitigate risks throughout production. 

Our custom metal fabrication ensures that the components produced are made to meet the demands of your specific application. With careful design analysis and material selection, we ensure each component is optimized for durability, strength, and long-term performance.

Get Your Products to Market More Quickly

Using advanced machinery and innovative techniques, The Federal Group streamlines every step of the manufacturing process to make it more efficient. With a global network of supply partners, we put our extensive operational facilities to work to scale production and help you deliver on schedule.

We reduce fabrication costs and product development cycles by focusing on efficiency throughout the design process. Working with our experienced engineers and fabricators, you can achieve high-quality parts quickly and reliably to stay ahead of the competition. 

Transform Your Industry with Our Metal Fabrication Expertise

Headquartered in Michigan, TFG USA is a United States-based metal fabrication shop with a global reach. Launched in 1980, we have a long track record of providing customers with reliable fabrication solutions. Our metal fabrication capabilities cover a wide range of applications and manufacturing needs, from short-run prototypes to high-volume production runs. With world-class precision fabrication and rigorous quality assurance, you can rely on us to deliver high-quality products every time.

Whether you need precision parts for agriculture and storage applications, sheet metal parts fabrication for heavy trucks, or metal components for medical equipment, we deliver uncompromising quality and reliable service. Our global connections, resources, and high-tech facilities ensure efficient production and cost-effective solutions for projects at any scale.

Explore Our Comprehensive Metal Fabrication Services

Metal fabrication requires specialized machines to shape metal into precise, custom forms. At The Federal Group, we use state of the art equipment like CNC and laser cutting machines to offer a complete range of essential metal fabrication capabilities, including metal stamping, hot extrusion, and more. With our advanced tools and industry experience, we can handle any custom metal fabrication project, delivering high-quality components tailored to your exact specifications.

• Casting: There are a number of different methods for casting, including sand casting, investment casting, and die casting, to name a few. Each method has its strengths, but for projects requiring flexibility and cost efficiency, working with a trusted sand casting manufacturer can provide tailored solutions that meet specific design and production needs.
• Cutting and Bending: Whether you’re working with thin sheets or thick metal plates, cutting and bending are fundamental processes used to shape metal into usable components. As a leading custom metal fabrication company, TFG uses a wide range of techniques, including automated cutting tools and press brakes, to achieve accurate cuts and bends.
• Finishing: The final step in the metal fabrication process, ensuring that your parts match your exact specifications for durability, corrosion resistance, and aesthetics. At The Federal Group, we offer a comprehensive range of finishing services, including painting, powder coating, galvanizing, anodizing, sandblasting, and custom CNC machining. 
• Folding: Similar to bending, metal folding can deliver high-quality components with complex geometries. Folding along multiple axes or curved lines offers advantages, making this method ideal for three-dimensional projects where strength, precision, and minimal waste are the top priorities, such as for components like electrical boxes, brackets, and HVAC ducts. 
• Hot Extrusion: The process of forcing metal through a die to create a cross-sectional profile. This extrusion process is done at high temperatures, keeping the materials from work hardening and making it easier to push the material through the die. As a leader in custom metal fabrication, The Federal Group uses hot extrusion to fabricate aluminum, steel, and other alloys for a wide range of applications.
• Laser Cutting: Laser cutting uses programmable laser cutters to cut most metals. Although this is an exceptionally precise and versatile metal fabrication process, this process can be expensive due to the amount of electricity needed. Also, depending on the material, the thickness of the metal that can be cut is limited, typically ranging from ¼ to 1 inch. 
• Metal Spinning: Also known as spin forming, metal spinning is a custom metal fabrication process that produces cylindrical, conical, and other hollow shapes. Starting with a flat metal disc or tube, the material is shaped by a CNC lathe rotating at high speed. As the material spins, high pressure is applied to form it into a specific shape.
• Metal Stamping: A metal forming company uses metal stamping to shape flat metal sheets with precision and speed. 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 and can be performed on both sheet metal and rolled materials.
• Sheet Metal Fabrication: Custom sheet metal fabrication can include a combination of processes, including cutting, bending, finishing, and assembly. Together with advanced technology and state-of-the-art equipment, our expertise in sheet metal fabrication allows us to create quality products for a variety of industries.
• Water Jetting: Also known as waterjet cutting, water jetting 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, and it’s ideal for metals that are sensitive to heat distortion, such as stainless steel.
• Welding: When two pieces of metal are joined together using fusion, achieved through high temperatures and a filler metal material. The welding process can involve a chemical flame, electricity, pressure, or lasers to generate the heat necessary to join the metals. For all types of weldable alloys, our experienced team employs various types of welding, including oxyacetylene, tungsten inert gas (TIG), metal inert gas (MIG), and shielded metal arc welding.

Experience Cutting-Edge Innovation in Metal Fabrication

The Federal Group USA delivers superior quality by leveraging the latest advancements in metal fabrication. We combine precision engineering and cutting-edge equipment with decades of experience. Our state-of-the-art facilities employ industry-leading technology to achieve faster production times and reduced costs while producing components with tight tolerances and complex geometries. 

From rapid prototyping to high-volume manufacturing, our innovative metal fabrication techniques include advancements such as robotic automation, CNC machining, laser cutting, and water jetting to achieve unmatched precision, even when working with special metals and superalloys.

Unlock the Power of Customization and Flexibility in Metal Fabrication

Standard, off-the-shelf components don’t always meet the demands of your project. At The Federal Group, we go beyond a one-size-fits-all approach to deliver fully customized solutions for your metal manufacturing project. Rather than relying on pre-made components, developing custom metal parts and components provides distinct advantages. 

Partner with The Federal Group for custom metal fabrication services that match your project requirements. We understand the need to keep your production line moving, and by providing fast turnarounds for both short and long run production cycles, we ensure you receive high-quality parts without delay. Contact us today to discuss your project and experience the quality and precision that we offer at every stage of production.

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 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 material handling and planning 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 45+ years and we are eager to learn more about your next project. Contact us today for a free quote.