How Sheet Metal Fabrication Works

Sheet metal is ideal for a variety of manufacturing  projects because it’s strong, durable, and malleable. Design and engineering professionals in multiple industries use sheet metal to build everything from heavy equipment parts to commercial construction projects.

What Is Sheet Metal? 

Sheet metal is any metal shaped into thin, flat pieces through various industrial processes. Sheets of metal are typically less than six millimeters thick, although you can make them thicker or thinner depending on your needs.

Common metals used to make sheets include:

• Stainless steel
• Mild steel
• Tin
• Nickel
• Titanium
• Aluminum
• Brass
• Copper

We use sheet metal instead of raw metal because molding and forming it into different shapes is easy.

One of the key advantages of sheet metal is its ability to maintain structural integrity during the fabrication process. This means that even when sheet metal is cut, bent, or stretched into various shapes, it typically retains its strength and does not easily deform. This property is crucial in ensuring that the final product remains durable and reliable. 

Additionally, sheet metal materials have a good strength-to-weight ratio, meaning sheet metal can strengthen your finished products without weighing them down.

Sheet Metal Fabrication Process

Cutting Techniques

Metal fabrication services allow you to cut sheet metal in different ways depending on its intended use. Common techniques include:

• Laser cutting involves using a laser to cut sheet metal. This cutting method offers flexibility, precision, speed, and repeatability, allowing you to create raw materials consistently. It is best suitable for complex and detailed designs. 
• Plasma cutting involves using ionized gas to cut metal precisely and is commonly used for cutting through thicker metal.
• Water jet cutting involves cutting your sheet metal with a high-pressure stream of water mixed with an abrasive such as garnet or sand. This versatile method minimizes heat damage. This process is perfect for heat-sensitive materials. 
• Mechanical cutting involves using machines to saw or shear your sheet metal. A band saw or similar cutting tool is suitable for straight cuts and thicker metal. Shearing uses two offset blades and a clamp. Shearing gives you cleaner cuts with less wasted material.

Forming Techniques

Precision sheet metal fabrication relies on these forming techniques: 

• Bending uses force to form components into your desired shape, essential for creating structural components.
• Roll forming is used for continuous bending of long strips of metal, perfect for creating complex shapes with consistent cross-sections.
• Deep drawing involves using tools such as punches, dies, and binders to punch a piece of sheet metal into a particular shape. It’s often used to make components such as appliance housings, kitchen sinks, and industrial containers.
• Hydroforming is a form of deep drawing that uses high-pressure rubber as a mold and pressurized water to shape the metal. It is commonly used for creating seamless parts. 
• Stretch forming also uses a die or a form to shape metal bent via stretching. This process is often used in manufacturing to create components such as architectural panels, window frames, and complex curved shapes for construction equipment.
• Ironing lets you create a piece with uniform thickness by forcing metal through various dies and decreasing clearance to stretch it. It’s often used to make aluminum cans. 
• Curling involves forming the edges of your metal to create a hollow ring at the edge of a sheet. You would do this to remove sharp edges and make parts safer to work with.

Joining Techniques

Once you’ve shaped your sheet metal, you need to join it. Common joining techniques include: 

• Welding, or melting metal to join two pieces. It provides a strong bond but requires skilled technicians 
• Riveting uses small fasteners for a durable connection, suitable for heavy-duty applications
• Clinching, which involves joining thin sheets using machinery to interlock them without additional components. It is ideal for lightweight applications
• Sheet locking, which is akin to a zipper on your clothes, involves forming two edges of sheet metal into hems you can lock in place by fitting the fingers of one side into the fingers of another. However, it may be more expensive due to its complexity

Choose your joining technique based on the process cost and the precision you need in your final product. Custom techniques, such as clinching and sheet locking, are more precise, but welding and riveting are often more affordable.

Applications of Sheet Metal Fabrication

Above: A custom metal sink manufactured by the aluminum fabrication process.

Sheet metal is used to make everyday products and objects like appliances, agricultural equipment, construction machinery, industrial storage solutions, and hospital machinery. Anything you see made with metal components was likely crafted with sheet metal specifically fabricated for the product.

You would fabricate sheet metal when you want a strong, durable structure, such as a balcony or a staircase, but you don’t want to weigh down your final product. Because metals like aluminum and titanium are lightweight and resist corrosion, many companies use them to create structures like outdoor furniture, signage, and equipment enclosures.

Advantages and Disadvantages of Sheet Metal Fabrication

Versatility in Design

Because sheet metal can be made with different types of metal, it offers maximum flexibility. Sheet metal allows for diverse designs and complex shapes, and it can be used to make anything from a stainless steel refrigerator to industrial machinery components.

Manhattan’s Chrysler Building features sheet metal detailing, highlighting its form and function. 

Strength and Durability

Regardless of its base metal, sheet metal has a high strength-to-weight ratio, making it suitable for a wide variety of functional parts. Lightweight material improves performance and fuel efficiency in ships, and. Lightweight and durable materials are also great for commercial appliances and building parts.

Cost Considerations

Because you can use dies and other machinery in sheet metal work, it helps make production cost-effective. You just need to set up your operations and get a reliable, repeatable process so each item you manufacture is consistent. Mass-producing your sheet metal makes it more cost-effective.

Production Speed and Efficiency

Sheet metal fabrication techniques, such as laser cutting and deep drawing, use technology that gives you precise results every time. You can easily use machines for fast and efficient manufacturing to meet high-volume demand with high quality. 

Surface Treatments and Finishing Techniques

While sheet metal itself is not inherently corrosion-resistant, you can enhance its durability and longevity through various surface treatments. Some of the most popular examples are listed below:

• Powder coating provides a protective layer that is resistant to chipping, scratching, and fading, making it ideal for outdoor and high-use applications.
• Anodizing: commonly used for aluminum, it increases resistance to corrosion and wear by thickening the natural oxide layer on the metal’s surface.
• Electroplating, such as gold-plating, adds another layer of metal for both decorative and functional purposes, often used in jewelry and home goods.

For industrial applications like pharmaceutical machines, surface treatments can ensure the metal meets stringent hygiene standards and withstands rigorous cleaning processes. 

Lastly, a raw or rough finish might be suitable for applications where aesthetic appearance is less critical. For a matte finish, sandblasting or bead blasting can be employed to achieve a smooth and uniform surface, enhancing both appearance and functionality.

Innovations and Trends in Sheet Metal Fabrication

Technology has made sheet metal fabrication techniques even more precise. You can use 3D printers for prototyping, so you don’t have to waste sheet metal and other raw materials to test your designs. Computer numerical control (CNC) machinery uses algorithms to make cutting and fabricating sheet metal highly accurate for consistency. By being more precise, you can cut back on waste and reduce your environmental impact. 

Sheet Metal for Strong, Durable Product Components

Sheet metal manufacturing produces strong product components that will stand the test of time. The Federal Group offers custom sheet metal components, combining expert engineering with the latest manufacturing processes. 

Contact us to learn more about how we can provide you with custom sheet metal fabrication services.