Sheet metal fabrication is a process of working with metal, used in various industries, ranging from construction and automotive to warehouse and electronics.
It involves transforming flat sheets of metal into functional components and structures through material cutting and bending, forming and assembling.
CSM has more than three decades of experience in designing and producing high-quality bespoke metal fabrications that fulfil exacting fit, function and aesthetic requirements.
In this comprehensive guide, we discuss the sheet metal fabrication meaning, history, processes, applications, and how to find the right supplier for your project.
Common Materials Used in Sheet Metal Fabrication
Various metals and alloys are employed in sheet metal fabrication, each possessing unique properties suited for specific applications. The most commonly used materials include:
Steel: Steel is a popular choice due to its strength, durability, and cost-effectiveness. Carbon steel, stainless steel, and galvanized steel are commonly used in different applications, from materials handling solutions and custom brackets to secondary building structures and aesthetic architectural pieces.
Aluminium: Aluminium is lightweight, corrosion-resistant, and an excellent conductor of heat. It is widely used in industries like aerospace and electronics.
Copper: Copper offers excellent electrical conductivity and is often used in electrical components.
Brass:Brass, a combination of copper and zinc, is valued for its attractive appearance and corrosion resistance, making it ideal for decorative applications.
Bespoke metal splashbacks with a patina finish
Applications of Sheet Metal Fabrication
Every sheet metal fabrication business will have its own specialisms.
For example, CSM specialises in three main areas, always offering bespoke projects for each client. That is as opposed to mass production of low-cost products.
Warehousing: We specialise in industrial metal fabrication for warehouses and factories, producing gantries, staircases, shelving, racking, bespoke trolleys and material handling equipment, brackets and other custom sheet metal work.
Bar work: We also specialise in bar tops and architectural metal – for fixtures, fittings, walls, entrances and so on via our sister company Volund.
General fabrication: This can include cones, brackets, arches, components for products, parts, gates, railings – the applications are almost endless.
Brass bar front
However, there are many more areas in which sheet metal fabrication is present. Some other examples include:
Construction: In construction, sheet metal fabrication services are used to create roofing, cladding, gutters, and HVAC ductwork.
Architecture: Architects often collaborate with fabricators to produce decorative panels, facades, feature staircases, and bespoke metal elements that add aesthetic value to buildings.
Design: Designers use fabricated sheet metal to bring concepts to life – including furniture, lighting fixtures, signage, and artistic installations.
Engineering: Precision components for machinery, enclosures, control panels, and structural supports are common uses within engineering fields.
Personal Projects: Hobbyists and individuals may require custom sheet metal work for home renovations, vehicle modifications, or artistic endeavours.
Commercial Fit-Outs: From retail displays and signage to fixtures, countertops, and partitioning, sheet metal is a key material in customising commercial interiors.
The Sheet Metal Fabrication Process
The sheet metal fabrication process involves several key steps:
Step One – Design and Engineering:
The process begins with detailed design. At CSM we work with clients closely to develop drawings and specifications that will deliver the best results in terms of cost, efficiency and effectiveness. We don’t have order takers or sales people – jobs are planned with skilled and experienced metal fabricators.
In some cases where required, computer-aided design (CAD) software allows designers to create precise 3D models of the components.
Layout design
Step Two – Material Selection and Preparation:
The appropriate metal sheet is selected based on the application and requirements. For an aesthetic finish you may choose Pewter, for durability you may choose steel. It all depends on the outcome.
The sheet is then cleaned and prepared to ensure a smooth and defect-free surface and the sheet metal is cut to size and requirement, ready to be worked with.
Materials
Step Three – Bending, forming and rolling:
When it comes to sheet metal engineering, there are several ways to work with metal:
Forming: The metal forming process involves shaping the metal sheet into the desired configuration.
Bending: The metal is bent to achieve angles or curves using press brakes or rolling machines.
Rolling: Metal sheets are passed through rolling machines to create cylindrical shapes like tubes.
Joining: Joining techniques are used to assemble multiple pieces of sheet metal. Common methods include:
Welding: Merging metal pieces through heat and often the addition of a filler material.
Riveting: Using rivets to hold metal pieces together.
Fasteners: Using nuts, bolts, and screws to join metal components.
Finishing: The finishing process involves cleaning, smoothing, and coating the fabricated metal components to improve aesthetics and protect against corrosion.
Polishing: This is just one of the techniques used to give an aesthetic finish to projects.
CSM team member rolling metal
Sheet Metal Fabricators: Finding the Right Partner
Finding the right sheet metal fabrication supplier is essential for a successful project. You need someone who understands more than just the sheet metal fabrication basics. Here are some tips to help you in the selection process:
Experience and expertise: Look for companies with good experience and expertise in your area. If you were looking for a bar top or bespoke warehouse fixings, CSM would be a great choice, while for medical equipment, you may be better off consulting a specialist in that area.
Capabilities and equipment: Check that the company has the necessary equipment to handle your specific project requirements. For example, at CSM we have a lot of machinery needed to create the specific projects we work on, but not necessarily the machinery needed for micro-components.
Quality control: Inquire about the company’s quality control processes to ensure that the final product meets your high standards. For example, CSM is ISO 9001 certified and has CHAS accreditations.
Location: If you prefer working with a local supplier, search for “sheet metal fabrication near me” to find options nearby. However, a good cultural match is usually better than choosing somebody just because they’re local.
References and reviews: Seek references and customer reviews to gain insights into the company’s reputation and customer satisfaction. You can even ask to speak to old customers – reputable companies are usually happy to facilitate.
Benefits of Sheet Metal Fabrication
Wondering if sheet metal fabrication is the right avenue for your project? When you work with a specialist like CSM, you can rely on our skills and expertise to turn complex briefs and ambitious designs into fully functioning, expertly-crafted custom products.
You’ll benefit from:
Strength and durability: With custom metal fabrication services, you can choose a material with properties to suit your specifications, ensuring the finished product will perform well in its intended function and setting.
Versatility and customisation: Specialist fabricators open up a world of possibility, applying expertise and state-of-the-art machinery to create the specific, niche and unique parts you need.
Cost-effectiveness and mass production: Your custom design can be produced in large quantities to address common challenges quickly and effectively.
Speed and precision with modern technology: With leading software, tools and machinery, sheet metal fabricators can quickly produce very specific and intricate components to exacting specifications.
Environmental and sustainability: Design and fabrication techniques like CNC machining increase precision and accuracy, reducing human error and material wastage.
Sheet Metal Fabrication – quick-fire FAQs
What is a sheet metal fabricator?
A sheet metal fabricator is a skilled professional who transforms flat metal sheets into various shapes and products for different industries through a range of sheet metal processing techniques.
What is precision sheet metal fabrication?
Precision sheet metal fabrication is the production of metal components with extremely tight tolerances and exact specifications.
What are the different types of sheet metal fabrication?
Sheet metal manufacturing processes include cutting, forming, bending, joining and welding. You can learn more about each of these processes and the technologies used in our blog.
What materials are used in sheet metal fabrication?
A range of different metals – commonly varieties of steel, aluminium, copper and bronze. At CSM, we also work with brass, pewter, zinc and titanium.
Getting Started With Sheet Metal Fabrication
Sheet metal fabrication is a fundamental process that has shaped the modern world in numerous ways.
Whether you need a custom sheet metal component, architectural fabrication, or precision parts, understanding the sheet metal fabrication process, techniques, and finding the right supplier will help you achieve successful and cost-effective results.
At CSM, what we don’t know about sheet metal fabrication isn’t worth knowing! We combine three decades of experience, expert craftsmanship, state-of-the-art machinery, and passion to produce high-quality, bespoke metal fabrications. We can work with you throughout the entire process, from design to installation, or simply support parts of your project.
Bespoke metal splashbacks with a patina finish
Brass bar front
Layout design
Materials
CSM team member rolling metal