The Federal Group has been a leader in metal fabrication services for nearly 40 years. We work with companies across a variety of industries to produce high-quality custom metal products and to keep your development cycle on track.
Quality Metal Fabrication for Any Project
We offer a complete range of sheet metal fabrication capabilities, including:
- Metal stamping
- Hot extrusion
- Folding or bending
- Laser cutting
- Water jetting
- Metal spinning
- Stainless steel fabrication
Producing a custom metal part in a specific desired shape requires specialized fabrication equipment. We use a variety of tools for metal fabrication such as a CNC machine, laser cutting machine, or water-jetting machine. At The Federal Group, we have the materials, machinery, and experience to handle any custom metal fabrication project.
The Advantages of Custom Metal Fabrication
Many products rely on ready off-the-shelf components. However, when creating a custom fabricated product, developing custom parts and components provides many distinct advantages:
- Produced with top of the line equipment
- Utilizes highest quality materials and alloys
- Produced by skilled engineers that pay attention to detail
Working with a custom fabrication shop ensures that your parts are made specifically for your application. We have facilities with the latest machining and fabricating equipment. Welders, millers, and CNC machines are just a few examples.
Along with the latest equipment, you receive the best materials. If you’re unsure of the best metal or alloy to use for your project, our team has the experience needed to help with your selection. We understand the differences between alloys and how they are affected by various environments and applications.
We understand the need to keep your production line moving. Contact us for customized fabricated parts with a shorter turnaround compared to smaller operations.
How We Form Metal
The Federal Group has the capability of forming metal in a number of ways.
Stamping is when a metal sheet is 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 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 is when two pieces of metal are joined together using fusion. Different types of welding include oxyacetylene, tungsten inert gas, 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
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.
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 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 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 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
We provide full-service metal fabrication services, working with you from product research 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 Capabilities
Along with fast results, we have the capability to work with a variety of metals. No matter the material, we have you covered. Common types of materials include most grades of:
- Carbon steel
- Stainless steel
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 options include painting, galvanizing, anodizing, 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 an Experienced Michigan Metal Fabrication Company
We are a U.S.-based fabrication shop with a global reach. TFG USA is headquartered in Southfield, 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:
- Consumer products
- Heavy truck and recreational vehicles
- Hobby and toy
- Off-highway and railway
Our 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 products 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.
Do not cut corners when it comes to your project. Partner with a team that works with you to develop precision custom metal products. Contact The Federal Group USA today to discuss your project.
The Federal Group’s Metal Fabrication Capabilities
At The Federal Group USA, we produce a diverse range of products and assemblies via metal fabrication for a vast array of industries, including automotive, motorcycle, electrical, industrial, medical, restaurant, information technology, handicap mobility, vending equipment, mining, signage, transportation, and construction, just to name a few. Whatever your project, from sturdy steel frames and machine components to grills and decorative motifs, our engineers and staff will find a way to make your fabrication plans a reality.