About Metal Fabrication

The Federal Group has the capability of Forming Metal in a number of ways.

    • Stamping – a metal sheet is hit with a die at high pressure to create a specific shape in the metal.  A specific form of stamping, punching is when a press is used to force a die into metal creating a hole, many holes, embossing, or other shapes. The piece that is removed from punching is called the scrap slug and while normally performed on sheet metal, can also be done on rolled materials.
    • Hot extrusion – – extrusion is the process of forcing metal through a die to create a cross-sectional profile. This extrusion process is done at increased temperature, which keeps the materials from work hardening along with making the procedure of pushing the material through the die simpler.
    • Welding – when two pieces of metal are joined together using fusion. Different types include oxyacetylene, tungsten inert gas, shield metal arc, and gas metal arc welding. Welding is done at a high temperature often with a filler metal material and can involve a chemical flame, electricity, pressure, or lasers to achieve the heater needed to join the metals.
    • Folding or Bending – when force is applied to the metal material to alter its shape. The metal is bent manually by hammer or hydraulically with press brakes.
    • Laser cutting – programable laser cutters can be used 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 is can also be expensive due to the amount of electricity needed.
    • Water-jetting – Water-jetting is an alternative to laser cutting, it uses a thin jet of water under as much as 90,000 PSI to cut through metal thicker than that of a Lasers Capability.
    • Metal Spinning or Spin Forming – is a process in which a sheet of metal in disc form or a tube of metal is shaped by hand or using a CNC lathe rotating at high speed and exerting pressure to the material to form it into a specific shape. This process is like how a pottery maker forms clay.
    • Finishing – after a metal part goes through all the metal fabrication steps required to create the desired shape and
      purpose, the piece may be sand blasted, painted, powder-coated or anodized before being inspected and shipped to
      the customer.

The Federal Group’s Metal Fabrication Capabilities

At The Federal Group USA we produce a diverse range of metal fabrication products and assemblies 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.