What Exactly Is Sheet Metal Fabrication?

Sheet metal fabrication is the process of turning flat sheets of steel or aluminium into metal structures or products, by cutting, punching, folding and assembling. Sheet metal can be cut, bent or stretched into nearly any shape, which is generally done by cutting and burning the metal.

How the Sheet Metal Fabrication Process Works

Metal fabrication begins with processing raw materials, often large and thick, such as steel, aluminum, and copper. Sheet metal is then cut, bent, or stretched into the desired shapes. Below are the typical steps involved in the process:

1. Design

The design stage forms the foundation of the project. Designers create initial sketches or 2D/3D models of the product, usually using computer-aided design (CAD) software or by hand. This phase outlines essential factors such as the product's intended use, required dimensions and tolerances, and any specific materials or finishes needed before manufacturing begins.

2. Cutting

Laser cutting is generally the first step in the manufacturing process. It is one of the most precise methods for cutting sheet metal, as lasers can follow the programmed design with high accuracy and cut through the material cleanly.

3. Bending

Bending, also known as CNC folding, is performed using machines such as manual press brakes or automated panel bending machines. The machine clamps the sheet metal and applies pressure to achieve the desired curvature.

4. Forming

Forming reshapes the material into the required shape without removing any material, unlike cutting. This process deforms the metal while maintaining its mass, which can result in various shapes and structures based on the project's specifications.

5. Welding

Several welding techniques are used in sheet metal fabrication, including:

• MIG (Metal Inert Gas) Welding: A fast process ideal for thicker materials.
• TIG (Tungsten Inert Gas) Welding: Offers higher precision and control, suitable for thinner materials.
• Robotic MIG Welding: An automated version of MIG welding for higher consistency.
• Spot Welding: Involves an electrical resistance process to join metal parts.

6. Finishing

Finishing is the final step to prepare metal products for use, enhancing their resistance to corrosion and improving durability. This stage also makes the surfaces more aesthetically appealing. Common finishing techniques include:

• Surface preparation
• Polishing
• Powder coating (in various colors)
• Anodizing
• Passivation
• Laser marking (such as logos or text engraving)

7. Assembly

In the assembly stage, the various components are put together before being packaged and delivered to their final destination.

This step ensures that all parts are properly aligned, secured, and ready for use in the intended application.

Major Types of Sheet Metal

Aluminium: Commonly used in automotive parts, electrical devices, and cooking vessels. It offers a great strength-to-weight ratio and high conductivity, making it ideal for a wide range of applications.

Aluminised Steel: This material combines the strength of carbon steel with aluminium’s excellent corrosion resistance. It is typically used in products exposed to high temperatures, such as kitchen appliances.

Carbon Steel: A versatile alloy used in both industrial and consumer markets. Carbon steel increases in hardness and strength after heat treatment, making it suitable for a variety of products.

Copper: Copper is known for its high electrical and thermal conductivity, which makes it ideal for applications such as sinks, roofs, rain gutters, and doors. However, it tends to be more expensive than aluminium.

Galvanised Steel: This steel is coated with zinc through a hot-dipping process to enhance its corrosion resistance. It is commonly used for automobile bodies, water pipes, fences, roofs, and staircases.

High-Strength Steel: Often used for military armour plates, this steel is alloyed with elements like carbon, manganese, and copper to improve hardness and durability.

Stainless Steel: Widely used in kitchen vessels, storage tanks for chemicals, and food processing machinery, stainless steel is valued for its excellent corrosion resistance, strength-to-weight ratio, heat resistance, and ease of manufacture.

Titanium: Known for its high strength-to-weight ratio and exceptional corrosion resistance, titanium is commonly used in aerospace parts, medical equipment, and construction elements. It is also recyclable, adding to its sustainability.

Applications of Sheet Metal Fabrication

Sheet metal fabrication plays a crucial role in a wide range of industries, whether for structural purposes, decorative elements, or functional components. Here are some common use cases:

Kiosks, Vending Machines & Enclosures

Vending machines and kiosks are essential revenue generators for many customer-facing businesses, such as gyms and leisure centers. Their construction requires precision, as they consist of numerous individual components. Sheet metal fabrication ensures these machines are built with durability and functionality.

Construction & Security

In the construction and security industries, sheet metal fabrication is used to create essential products like security doors, guard rails, security grills, and custom enclosures. These components provide safety and protection in various environments, from buildings to outdoor spaces.

Retail

Sheet metal fabrication is also used to design attractive and functional retail displays, which are essential in the retail sector. It helps create bar displays, display cubes, portable units, and point-of-sale stands that are not only visually appealing but also practical for showcasing products effectively.

Science, Medical & Food

The scientific, medical, and food industries heavily rely on sheet metal fabrication for items found in commercial and industrial kitchens, such as countertops, storage units, and sinks. Stainless steel is often the preferred material, especially in the food production and preparation sectors, due to its durability and hygiene standards.

Transportation

The transportation industry uses sheet metal fabrication for a wide array of components. For instance, emergency vehicles require custom-made parts like glove-box enclosures, side steps, door-handle mounts, and steel surrounds for tail-lift doors. Additionally, safety rails, ladder hatch trap doors, and stair-safe products are all made through sheet metal fabrication, ensuring safety and functionality in the transportation sector.

Benefits of Metal Fabrication

Sheet metal fabrication provides numerous advantages, with the three main benefits being:

1. Strength & Durability: Metal fabrications are highly durable and can last for many years with proper care. This makes them ideal for projects that require long-term performance and reliability.
2. Versatility: Metal fabrication can be applied to a wide range of projects, regardless of size, making it a valuable solution for both businesses and individuals.
3. Low Maintenance: Metal fabrications are resistant to rust, corrosion, fire, and heat, which makes them perfect for use in industrial and commercial environments, where longevity and reliability are essential.