Guide to Sheet Metal Manufacturing Processes

In metal fabrication, fabricators create metal parts from raw source metals like steel, copper or aluminium. They’ll use methods like cutting, punching, bending, and welding to fabricate the parts needed for a project. Sheet metal fabrication specifically uses all of the same processes, but only flat metal sheets are used as the source to create the products.

To make a decision about your project, you must understand the sheet metal fabrication process. So, this guide explains the processes, materials and techniques involved in sheet metal fabrication. It will help you to be certain your project meets all necessary specifications to achieve your desired outcome.

What are the main processes in sheet metal fabrication?

Below, we’ll explain the most common metal manufacturing processes:

Cutting

The first step in the sheet metal fabrication process is cutting, which is where the fabricators will slice the raw materials into the parts needed to complete a project. Getting precise cuts is critical. Even the odd millimetre in the wrong direction can throw the finished product out of alignment.

Techniques:

  • Laser cutting: This is an extremely precise method to cut metal. It uses a focused laser beam to get an accuracy of in the region of ±0.0127mm. Using a laser in this way is best suited to complex designs, like custom metal splashbacks and decorative panels that might need detailed patterns and fine edges.
  • Plasma cutting: Plasma is a quick method of cutting that can slice through fairly thick sheet metal without an issue. Its accuracy is around 0.5–1mm, so this method is perfect for projects like heavy-duty structural components and industrial brackets.
  • Water jet cutting: Water cutting uses a high-pressure jet of water mixed with abrasive materials and cuts to an accuracy of about 0.05mm. This method cuts without heat, so it is better at preserving the original properties of the source material. Cutting in this way is often used for creating bespoke metal bar tops and precision parts. It’s great for any project that needs a smooth final finish.

Forming

Forming is where the fabricator bends and forms the metal into the right shape for the project. It is done without removing any material. This is where any required curves, angles or other shapes are created.

Techniques:

  • Bending: This is where the metal is held in place by a clamp and bent to the right angle. In terms of sheet metal forming processes, this is one of the most common. It’s used for end projects like custom metal bar tops—where clean lines and a seamless finish are needed.
    • Press Brake Bending: By pushing source metal sheets between a punch and die, a press brake creates the right angles for the metal to be used on a project. Press brake bending is often used for creating custom metal enclosures and architectural profiles that demand high precision and consistent bends.
    • Roll Bending: Roll bending can create cylinders and cones from the source metal by passing it through several rollers. This bending technique is perfect for creating large, curved components such as metal ducts and cylindrical tanks — anything that needs an accurate curve all the way around.
    • Air Bending: By partially pressing the metal sheet into a die, air bending can create specific angles. It’s great to create custom brackets and mounting where multiple angles are required without requiring different tooling setups.
  • Rolling: Metal is passed through rollers to create cylindrical or conical shapes, often used in architectural installations or industrial ductwork.
  • Stamping: A die is used to press shapes into the metal, often for mass production of parts. If you need a large number of uniform metal products, like metal brackets and fixtures, this is the process used to create them.

A fabricator welding sheet metal.

Joining

Joining processes connect different metal components to form a complete assembly. To make sure the final product has the right structural integrity and functions, this step is crucial.

Techniques:

  • Welding: This process joins metal pieces by melting the surfaces that come into contact with each other. Techniques of welding include TIG welding (for precision work) and MIG welding (for heavier structures). Our fabricators often use TIG welding on our metal splashbacks to make sure there’s no seam.
  • Riveting: Uses metal pins (rivets) to join sheets, commonly used in aerospace and construction. Architectural metal railings sometimes use riveting to join the sections of aluminium or steel together. Riveting gives a strong connection for the outdoors because it can withstand harsh weather conditions.
  • Adhesive Bonding: This uses strong adhesives made for industry to join metal components together. It’s most often used when manufacturing automotive and parts and appliances. If a project needs a sleek finish without obvious joins, we’ll likely use adhesive bonding — a good example is metal splashbacks.

Finishing

Finishing is the final step in the sheet metal fabrication process. It gives the metal components their final state of corrosive resistance, durability and appearance. The right finish increases the functionality of the finished product and gives it the right look for the project.

Techniques:

  • Powder Coating: Powder coating is applied when we need to add a protective layer to the metal. To do it, we’ll add a dry powder to the metal surface and then cure it under a high heat. Powder coating is ideal for products like custom metal shelving and exterior architectural elements, where durability and a high-quality finish are required.
  • Anodising: This electrochemical process enhances the natural oxide layer on the surface of metals, primarily aluminium, improving corrosion resistance and allowing for colour finishes. If a project needs a decorative finish that lasts — for example, in outdoor signs — then anodising will likely be used.
  • Galvanising: Involves coating the metal, typically steel, with a layer of zinc to stop it corroding. This process is ideal for industrial applications that need long-term protection against rust — so metal railings and outdoor structures would be an example.

What materials are used for sheet metal fabrication?

Cladded walls added to a restaurant entrance by CSM

There are several different metals commonly used in sheet metal fabrication for reasons like their strength and corrosion resistance. Here are some of the most commonly used metals:

  • Stainless steel: This metal is great for its resistance to corrosion and strength. Because of this, stainless steel is often used in food processing, medical equipment, and architectural projects.
  • Mild steel: A versatile and cost-effective material, mild steel is most often used in construction, automotive, and general manufacturing.
  • Aluminium: This metal is resistive to corrosion and lightweight, so aluminium is widely used across the aerospace, automotive, and consumer electronics sectors.
  • Copper: Copper is a metal well known for its electrical conductivity and ability to be shaped. It’s most often used in plumbing and electrical wiring.
  • Brass: Brass is an alloy of copper and zinc, and brass is used in decorative applications and fittings due to its corrosion resistance and aesthetic appeal.

Want to discover more about what metal to use on your project?

You can find out more about the benefits of each metal in our guide to the common types of metal used in fabrication.

What tools and equipment are used in sheet metal fabrication?

Sheet metal fabricators use quite a few tools to achieve their cuts, bends and joins, including:

  • Press Brake: Essential for bending sheet metal into various angles and shapes.
  • CNC Machines: Computer-controlled machines that ensure high precision in cutting, drilling, and forming metal parts.
  • Welding equipment: Various welding machines join metal components, such as TIG and MIG welders.
  • Punch Press: Used for punching holes or shapes into the metal sheet, often used in mass production.

What design considerations should I consider when using sheet metal in my projects?

When designing for sheet metal fabrication, several factors need to be considered to ensure your final product has the specs and functionality you need:

  • Material selection: Choose a suitable source metal based on how your final product will be used. You’ll need to think about the strength, corrosion resistance and functionality.
  • Thickness: How thick do you need the final product to be? Because this will affect the thickness of the source metal. The thickness of the source sheet metal will affect the fabrication process and your final product’s strength and flexibility.
  • Tolerance: You’ll need to define the precise tolerances of your end project. This will help the fabricators to make sure all parts fit together correctly during assembly.
  • Bend radius: Consider the minimum bend radius for the chosen material. Getting this measurement right will prevent cracking or deformation during the bending process.

 

Bespoke fabricated cones made from the right type of metal for their purpose.

 

Ready to get started?

If you’re ready to explore how sheet metal fabrication can benefit your project, our team at Customised Sheet Metal is here to help. With our extensive experience in sheet metal fabrication services, we can guide you through the entire process—from design to production. 

Contact us today to discuss your requirements and get started.

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