Guide to Common Types of Metals Used in Fabrication

The success of your fabrication project hinges on the very first question: which metal should you use? This is because different metals offer unique properties that make them suitable for specific applications. 

This guide explores the most common types of metals used in fabrication, helping you understand their strengths, weaknesses, and suitability for different projects. 

Looking for a guide on how to choose the right type of metal for your project? It’s at the end of this article; click here to go straight there.

Why is selecting a suitable metal for your fabrication project important?

You’ll need to take all of the following considerations into account before deciding on your project’s material:

  • Structural integrity: Not all metals can carry the same strength, so if your project needs to take a great weight, you’ll need to consider how much. For example, mild steel is ideal for load-bearing tasks due to its high tensile strength.
  • Durability and longevity: Metals like stainless steel and aluminium resist corrosion, so they are better for projects that will sit outside. How much metal corrodes also impacts how often you’ll need to maintain or replace it.
  • Cost-effectiveness: The more durable a metal, in general, the more expensive it is to purchase. However, this can pay off in the long run because they offer long-term savings by reducing maintenance needs and repairs.
  • Customisation and flexibility: Not all metals are easy to shape, so if you need design flexibility or for the metal to meet a certain aesthetic, then you should consider this. A metal like aluminium can usually be formed to what you need.
  • Environmental suitability: If your finished metal needs to be outside or in a more harsh environment, then you’ll have fewer options. In these conditions, stainless steel is commonly the best choice.
  • Quality control and compliance: Your choice of metal may well be pre-determined by industry standards. Check whether your choice is compliant before fixing upon your decision. 
  • Lead time: The choice of metal can affect lead time. We can offer a faster turnaround on more readily available metals like mild steel, while specialised metals may take longer for us to procure.

What metals are used in fabrication?

Mild Steel

Examples of steel source material

Mild steel is versatile and affordable, which is why it’s one of the most common metals for fabrication.

It offers good tensile strength and can be readily welded, cut, and formed into various shapes. However, it’s a ferrous metal, which means it contains iron and is prone to rusting, so it’s often used in projects where the metal will be painted or coated. 

This type of steel is ideal for structural applications, automotive parts, and machinery components.

Ideal for:

  • Structural frameworks: Mild steel is strong and affordable, especially when purchased in bulk. This means it’s often used for structural frameworks and infrastructure projects.
  • Automotive parts: This type of steel is used in fabricating some automotive components, such as chassis and brackets. It’s great for projects that need durability that’s cost-effective.
  • Custom metal enclosures: Mild steel is often used to create robust enclosures and housings for machinery and electrical equipment.
Galvanised Steel

Galvanised steel is mild steel that is protected from corroding by a layer of zinc. It’s an excellent choice for any project where the finished metal will be exposed to the outdoors.

Galvanised steel is commonly used in construction, fencing, and roofing. The zinc coating also adds a bit of extra durability, though it can wear away over time if not properly maintained.

Ideal for:

  • Outdoor structures: Galvanised steel is often used for railings, gates and outside structural supports because of its corrosion resistance.
  • Industrial shelving: Steel is ideal if you need heavy-duty shelving systems that need to withstand a lot of weight and usage.
  • Custom signage: This type of steel is great for any outdoor signs that need to resist rust and weather over time.
Stainless Steel

Stainless steel is very corrosive resistant, which is due to its chromium content. This metal is strong, durable, and resistant to staining, making it ideal for applications in food processing, medical equipment, and architecture. 

This steel can be challenging to work with due to its hardness, but it’s well-suited to welding, machining, and polishing. It’s most often used in projects where both strength and aesthetics are important.

Ideal for:

  • Custom metal splashbacks: Stainless steel is ideal for creating durable, easy-to-clean splashbacks. You’ll see it used in residential and commercial kitchens.
  • Architectural handrails and railings: It’s used to create custom metal handrails and railings because it’s great for being used outside.
  • Medical equipment: Because it doesn’t corrode, stainless steel is commonly used for medical-grade equipment and instruments that require high hygiene standards.
Aluminium

aluminium fabrication example

Aluminium is lightweight yet strong, making it a popular choice for aerospace, automotive, and consumer electronics applications. It’s also resistant to corrosion, especially when anodised, which makes it suitable for outdoor use. 

This light metal is easy to work with and can be cut, welded, and formed with relative ease. However, it’s less strong than steel and can be more expensive.

Ideal for:

  • Custom metal splashbacks: Due to its light weight and corrosion resistance, aluminium is often used to create splashbacks for kitchens and commercial spaces.
  • Architectural panels: Aluminium is easy to fabricate and versatile, so it’s often used for outside cladding or interior panels.
  • Bespoke metal signs: Aluminium is often used for custom signage due to its lightweight nature and ability to be anodised for a long-lasting, attractive finish.
Pewter

Pewter is an alloy that can be readily shaped. It’s mainly composed of tin and is easy to cast. Because it has a smooth finish, it’s most commonly used in decorative items like tableware and jewellery. 

While it’s not as strong or durable as other metals, pewter is easy to fabricate and looks good. It’s not suitable for structural applications but is excellent for bespoke fabrication projects that need to focus on appearances.

Ideal for:

  • Decorative items: Pewter is great for making decorative items like metal plates, bowls and ornaments because it’s very malleable.
  • Architectural accents: It’s often used in interior design for custom metal detailing. It can add a decorative flare to a base structure made from a less pliable metal.
  • Custom jewellery: Jewellery is often made from pewter because it’s soft and easy to shape. 
Zinc

Zinc is mainly used as a protective coating on other metals, such as in galvanised steel, but it also stands on its own as a fabrication material. It’s highly resistant to corrosion and is commonly used in roofing, cladding, and gutter systems. 

Zinc can be easily formed into various shapes because of its malleability. This makes it a good choice for any custom metal fabrication that requires complex, decorative designs.

Ideal for:

  • Roofing and cladding: Zinc is resistant to corrosion, so you’ll see it used for custom metal roofing and exterior cladding.
  • Custom gutters and downspouts: This metal is often used for creating bespoke drainage systems — ones that need to be functional and aesthetic.
  • Decorative architectural elements: Zinc metal can be used for decorative accents, for example window frames and cornices, to add an aesthetic finish to a building.
Brass

Brass is known for its distinctive gold-like appearance and excellent corrosion resistance. An alloy of copper and zinc, it’s most commonly used in decorative applications, plumbing fittings, and musical instruments

This golden-coloured metal is relatively easy to machine and polish, making it suitable for projects where aesthetics are essential. However, it’s not as strong as steel or stainless steel.

Ideal for:

  • Bespoke metal railings: Brass is a metal most often chosen because it’s durable and has a golden colour. These features mean you’ll see it used in decorative railings and balustrades.
  • Custom fixtures and fittings: This metal can be used to create door handles, taps, and other house fixtures. Places where the project needs a golden finish and resistance to corrosion.
  • Architectural features: Brass metal is used in architecture for trim, panelling, and inlays to give a slight aesthetic flare.
Copper

The Statue of Liberty against an overcast sky, a great example of architectural copper.

Copper is great at conducting electricity, so it’s used in electrical components and wiring. You’ll also see it used in marine environments because it is great at resisting corrosion. 

This metal is easy to work with and can be bent, soldered, and machined. However, it’s relatively soft, so it is rarely used structurally. Naturally, it has a red-brown colour. However, this quickly oxidises to green — as seen on the Statue of Liberty in New York — so it’s popular in architecture.

Ideal for:

  • Custom bar tops: Copper has a natural patina that gives it a warm colour and feel. Hence, it’s often used in hospitality, particularly to create bespoke bar tops.
  • Architectural features: This metal is used to create handrails, trims and roofing. Again, because of its aesthetic appeal.
  • Electrical components: Due to its conductivity, copper is used for high-quality, custom electrical components.
Titanium

Titanium has an impressive strength-to-weight ratio and is resistant to corrosion. Both of these properties make it ideal for use in aerospace, medical, and engineering.

However, this metal is expensive and fabricators can find it challenging to work with; because it’s so strong, it needs specialised equipment to cut and weld.

Despite these challenges, its durability and light weight make it worth the investment for critical applications.

Ideal for:

  • Medical equipment: Due to its biocompatibility, titanium is a metal material often used in the fabrication of custom medical instruments and implants.
  • High-performance components: Titanium’s strength-to-weight ratio makes it ideal for many more specialised industries.
  • Custom sports equipment: Titanium is used in custom fabricating lightweight, durable sports equipment such as bicycle frames and golf clubs.
Bronze

Bronze is known for its hardness, durability, and resistance to wear and corrosion. It’s an alloy of copper and tin that is most often used in bearings, bushings, and marine hardware. 

This brown-coloured metal has a distinctive appearance and is often used in sculptures and other decorative items. It’s relatively easy to cast and machine, so it’s suitable for many bespoke fabrication projects such as:

  • Sculptures and art pieces: Bronze is a historic metal and easy to work with, so it’s used a lot in sculptures and art installations.
  • Architectural features: Often used for high-end architectural features like door handles, plaques, and decorative panels, offering a rich, aged appearance.
  • Marine applications: Due to its resistance to corrosion in saltwater, bronze is ideal for custom metal fittings and components in marine environments.

Can other metals be used?

Absolutely. While we’ve covered the most common metals in sheet metal fabrication, other materials might be better suited to specific needs. For instance:

  • Nickel alloys: These are ideal for high-temperature environments, such as within gas turbine blades.
  • Magnesium: These are perfect for projects requiring ultra-lightweight materials, such as gearbox housing or the interior components for aircraft.

What is the environmental impact of fabrication?

Extracting, processing and fabricating the raw material metals has a significant environmental impact, in part due to the process’ high energy consumption, so it’s essential to make the most eco-friendly choices where possible.

The best way to remain environmentally conscious is in your metal selection because certain metals stand out for their eco-friendly properties:

  • Aluminium: Known for its recyclability, aluminium is a sustainable choice that requires significantly less energy to recycle than to produce new.
  • Stainless steel: Very durable and completely recyclable, stainless steel is another one of the top metal choices for projects that need to be eco-friendly.
  • Copper: Copper lasts a long time and can be recycled. The metal is also naturally antimicrobial, making it a sustainable choice for anywhere that needs to remain sanitary — for example, the bar top in a restaurant.

Another great way to offset some of the environmental impacts of your metal fabrication supplies is to purchase from responsible suppliers. At Customised Sheet Metal (CSM), we’re adopting the following practices to minimise our disruption to our planet:

  • Energy efficiency: The fabrication processes of our metal pure metal elements are designed to be energy-efficient, employing advanced machinery that minimises waste and maximises precision. This reduces our overall carbon footprint.
  • Waste reduction: As CSM, we make sure that scrap metal is either reused in future projects or recycled responsibly. This commitment to reducing waste aligns with our goal of lowering the environmental impact of our production activities.
  • Surface finishes: To extend the lifespan of our products and reduce the need for frequent replacements, we offer high-quality surface treatments such as powder coating and galvanising. These treatments make your manufactured metal more durable and reduce its environmental impact across its life cycle.

An example of architectural seel made into a bespoke birdcage design for Nando's restaurant.

Ready to Get Started?

Selecting the suitable metal is a critical first step to make sure your metal fabrication project is a success.

At Customised Sheet Metal (CSM), we’re here to help you make the best choice based on your unique needs. Whether you need advice on material selection or a comprehensive fabrication solution, our team is ready to assist. 

Contact us today to discuss your project.

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