Sheet Metal Fabrication Explained

What is Sheet Metal Fabrication

Sheet metal fabrication stands as a crucial pillar across numerous industries, spanning from construction and aerospace to automotive and beyond. This refined manufacturing process plays an integral role in crafting a myriad of everyday products.

While metal fabrication boasts a centuries-old history, it remains in a perpetual state of evolution, continually propelled forward by technological advancements. Its applications range from producing precision parts for machinery to erecting metal structures for buildings and bridges, underscoring its versatility and indispensability.

In this comprehensive guide, we’ll delve into the following aspects:

Understanding Sheet Metal Fabrication: Delve into the essence of sheet metal fabrication, unraveling its significance and relevance across various industries.

Process Insights: Gain insight into the intricacies of the fabrication process, exploring the methodologies and techniques employed to shape raw materials into functional components.

Types of Sheet Metal & Their Applications: Navigate through the diverse landscape of sheet metal varieties and their respective applications across different industries, from lightweight aluminum panels in aerospace to durable steel components in automotive manufacturing.

Advantages of Sheet Metal Fabrication: Explore the myriad benefits offered by sheet metal fabrication, ranging from cost-effectiveness and material efficiency to superior strength-to-weight ratios and design flexibility.

By immersing ourselves in these key areas, we aim to provide a comprehensive understanding of sheet metal fabrication, empowering readers to appreciate its significance and harness its potential across various industrial domains.

How the Sheet Metal Fabrication Process Works

Metal fabrication tends to start from processing raw materials, which are often large and thick – for example, steel, aluminium and copper. Sheet metal can be cut, bent or stretched into most desired shapes.

Here are the typical steps for how it works:

Design

The design stage is where the groundwork for the project is laid out. Designers will usually create initial sketches or 2D/3D models of the product, which may be done using computer-aided design (CAD) software or by hand.

Important factors such as the intended use of the product, the required dimensions and tolerances, and any specific materials or finishes that will be needed are mapped out before the manufacturing begins.

Cutting

Laser cutting is typically the first step in the manufacturing process. Laser cutting is one of the most precise ways of cutting sheet metal as the lasers are able to follow the programmed design and cut through the material accurately.

Bending

The bending process is known as CNC folding and is a practice that can be completed using a variety of machines. For example, a manual press brake or automated panel bending machine.

The machine forms the metal part by clamping the sheet metal and applying pressure to maintain the desired curvature.

Forming

The forming process bends or deforms the material into the required shape. Different from cutting, which subtracts the material, forming actually reshapes the material without decreasing any of its mass.

Welding

There are a variety of welding techniques that can be used when working with sheet metal, including MIG welding, TIG welding, robotic MIG welding and spot welding.

• Metal inert gas (MIG) welding: A typically fast welding option that is better for thicker materials.
• Tungsten inert gas (TIG) welding: Offers greater control and precision than MIG. Best for thinner materials. You may also see it referred to as gas tungsten arc welding (GTAW)
• Robotic MIG welding: This is an automated version of more traditional MIG welding.
• Spot welding: This follows an electrical resistance welding process.

Finishing

Finishing is the last step when preparing metal products for use and makes products more resistant to corrosion, adding another layer of durability. It also helps make the surfaces look appealing.

Common finishing touches could include surface preparation, polishing and powder coating in a choice of colours, anodising, passivation, and laser marking (such as logos or etching some text).

Assembly

In a sheet metal fabrication project, assembly refers to the assembling of the required products before they are packaged and delivered to where they need to be.

Major Types of Sheet Metal

Aluminium:

Used for automotive parts, electrical devices, and cooking vessels. Offering numerous benefits including a good strength-to-weight ratio, and high conductivity.

Aluminised steel:

This metal combines the high strength of carbon steel with aluminium’s superior corrosion resistance. Sheets of aluminised steel are used for products intended for high-temperature environments, such as kitchen appliances.

Carbon steel:

Carbon steel is used in the industrial and consumer markets for a range of products. It is a steel alloy that contains carbon, resulting in the material increasing in hardness and strength when it undergoes heat treatment.

Copper:

Examples of products made from copper are sinks, roofs, rain gutters, and doors. Copper features higher electrical and thermal conductivity in comparison to aluminium but can be more expensive.

Galvanised steel:

Sheets of galvanised steel tend to be used for making automobile bodies, water pipes, fences, roofs, and staircases. It is made by coating steel with zinc through a hot dipping process, helping to make it more corrosion-resistant.

High-strength steel:

Military armour plates tend to be made from sheets of high-strength steel. The material is produced by alloying steel with a range of elements such as carbon, manganese, and copper. This helps to improve its hardness.

Stainless steel:

Used for kitchen vessels, storage tanks for chemicals and food processing machinery. Stainless steel offers superior corrosion resistance, fire and heat resistance, strength-to-weight ratio, and manufacturability.

Titanium:

Typical products made from titanium include aviation parts, medical equipment, and construction elements. It is primarily used for its high strength-to-weight ratio and corrosion resistance. It is also recyclable.

Applications of Sheet Metal Fabrication

Kiosks, Vending Machines & Enclosures: Sheet metal fabrication plays a vital role in constructing kiosks, vending machines, and enclosures, ensuring durability and security for these customer-facing installations. These machines require numerous precision-crafted components, making sheet metal fabrication indispensable in their manufacturing process.

Construction & Security: In the construction and security sectors, sheet metal fabrication is instrumental in producing a wide range of products such as security doors, guardrails, security grills, and custom enclosures. These fabricated metal components provide structural integrity and enhance safety in various settings.

Retail Displays: Retail environments rely on visually appealing displays to attract customers and showcase products effectively. Sheet metal fabrication is used to create a variety of retail display units, including bar displays, retail display cubes, portable displays, and point-of-sale stands, combining aesthetics with functionality.

Science, Medical & Food Industries: Industries such as science, medical, and food production utilize sheet metal fabrication to manufacture essential equipment and infrastructure. In commercial and industrial kitchens, stainless steel fabrication is prevalent for worktop surfaces, storage units, sinks, and other sanitary fixtures due to its durability and corrosion resistance.

Transportation: The transportation sector heavily relies on sheet metal fabrication for producing a wide array of components used in vehicles. Emergency vehicles, for instance, require fabricated metal parts such as glove-box enclosures, side steps, door-handle mounts, and steel surrounds for tail-lift doors. Additionally, sheet metal fabrication is employed in constructing safety rails, ladder hatch trap doors, and other safety equipment used in transportation infrastructure.

By leveraging the capabilities of sheet metal fabrication, industries can achieve precision, durability, and versatility in manufacturing a broad spectrum of products tailored to their specific needs and requirements.

Make A Choice For Your Metal Fabrication

Krrass is a renowned company specializing in the manufacturing and distribution of sheet metal fabrication machinery. With a global presence and a reputation for excellence, Krrass has established itself as a leading provider of high-quality equipment for a diverse range of industries.

Founded in 1998, Krrass has grown steadily over the years, driven by a commitment to innovation, reliability, and customer satisfaction. The company’s extensive product line includes CNC press brakes, shearing machines, laser cutting machines, rolling machines, and more, catering to the varying needs of metalworking professionals worldwide.

Conclusion

Sheet metal fabrication is a versatile and widely used manufacturing process, offering a cost-effective solution for producing a wide range of products and components across industries such as automotive, aerospace, construction, electronics, and more. Its flexibility, efficiency, and ability to create complex shapes make it an essential part of modern manufacturing.