May. 19, 2025
When you need something made from metal, you need metal fabrication — but that could be as crude as the use of an arc welder and a portable cutting torch. When you need something manufactured from metal to more exact specifications, whether it’s for delicate metal decorations, steel construction beams, or something in between, what you really need is custom metal fabrication.
Link to ACE
Custom metal fabrication employs a wide range of industrial tools and equipment that can cut, bend, roll and join metal into complex shapes and assemblies. The most common metals used are carbon steel, stainless steel, aluminum and copper. Some applications call for specialty metals, so custom metal fabrication also employs metallurgy when needed to determine the best metal for the job.
Metal comes in two primary forms as a starting point for custom fabrication: sheet metal and structural metal.
Sheet metal comes in rectangular sheets or in rolls of various sizes and thicknesses. When sheet metal is 3/16-inch thick or greater, it’s commonly referred to as plate metal, and is often classified as plate.
Structural metal is metal stock that comes already formed into a particular shape, usually defined by its cross section. The most common shapes are beams, angles, channels, and hollow structural shapes, called HSS. A pipe is a type of HSS with a circular cross-section. Other profiles of HSS include square, rectangular and elliptical. Structural metal can also include specialty metal stock, such as prefabbed grating.
Three primary functions of a custom metal fabricator are: cutting the metal stock to desired shapes and sizes, forming the metal by bending or manipulating it in certain ways, and joining the elements of an assembly together.
Each of the primary processes breaks down into a variety of methods and types of equipment used for each, depending on the requirements of a particular custom metal fabrication job.
Metal Cutting Metal can be cut using specialized saws, shears, and sources of extreme heat, which can include high-definition plasma and laser cutters. A subset of cutting is punching, which creates holes or openings through pieces of metal.
Plasma tables are used to cut complex circles and curves.
SAWS: Industrial metal saws come in a variety of shape and sizes — usually large circular saws or specialty band saws that can cut most every type of metal, from plate metal up to giant construction I-beams. Saws are used for straight-line cuts. They are often used in “beam lines,” where the beams are sent down a roll conveyor to be cut to exact sizes dictated by architectural drawings.
SHEARS: Shears for custom metal fabrication are industrial machines of various sizes and configurations that cut sheet metal. Rated for different thicknesses, these machines cut the metal using opposing blades, similar to the operation of scissors, though one side is normally fixed while the other moves in an angled levering motion. Some, such as bench shears, are operated manually. Large shears are operated with hydraulics, including rams for holding the material in place. Shears are commonly used for straight-line cuts.
HIGH-DEFINITION PLASMA AND LASER: Industrial plasma tables allow for cutting plate metal into almost any shape or size. Plasma can cut custom shapes such as circles or complex curves and often is operated with computer numerical control (CNC). A plasma cut is somewhat cruder than laser. Laser cutting machines are used for extremely clean and precise cuts in almost any type of metal, and make it possible to create intricate shapes, such as decorative copper filigree.
PUNCH AND NOTCH: Industrial metal punch presses utilize dies that are struck against the metal to create openings of almost any shape or size, often using CNC. These high-pressure devices can make use of either mechanical, electro-mechanical or hydraulic force.
Custom metal work entails forming the raw stock into the desired shapes using industrial machines capable of generating the forces and pressures needed to alter the metal to precise tolerances.
ROLLING: While specialized hot rolling is used for the creation of raw metal stock, in custom metal fabrication cold rolling is most often used to shape sheet or plate metal into cylinders or curves. Plate rolling creates curves, while angle rolling creates defined angles, usually at 90 degrees.
PRESS BRAKING: Industrial press brake machines bend and form metal using high pressure and metal dies. A convex metal die is mounted into the press brake above a corresponding concave die mounted below. The metal to be shaped is inserted between them. Powerful hydraulic or mechanical force moves the convex die down toward the concave die, forcing the metal into it and bending it into the shape formed by the dies.
Once metal elements are cut and shaped, multi-element products need to be assembled and joined. For instance, a metal storage tank might have a cylindrical body, a dome top, a conical bottom, an access ladder, and various doors or hatches that all have to be assembled. Depending on the design, the assembly could include fasteners, such as rivets or nuts and bolts, or welding, requiring MIG, TIG or stud welding.Processes used to create finishes on metal can include blasting, passivating, galvanizing or painting.
With a consistent finish, this ductwork is ready to ship.
Custom metal fabrication is a complicated process. When you have a project that requires it, look for a fabricator that has as many capabilities as possible under one roof. This approach will keep costs, time and hassle down to a minimum.
With over 20 years in the business, Southern Metal Fabricators has all these capabilities and more. We’ve even got “ironworker” machines that combine several operations — such as press braking, punching, notching, and shearing —into one computerized workstation.
Last updated April
If you are looking for more details, kindly visit custom sheet metal fabrication.
The sheet metal fabrication industry has evolved significantly since da Vinci’s first sketch of an early sheet metal technique in . Today, it is a critical manufacturing process for sectors such as aerospace, construction, energy, and automotive.
Modern metal shops are more advanced than ever, leveraging cutting-edge technology and automation to improve precision and efficiency. In this article, you will learn what metal fabrication is and how the process works.
You use many products daily that are staples of the metal fabrication sector. Mailboxes, roof gutters, casings, and air-conditioning ducts/furnace flues are all examples.
Most metal fabricators work with sheet metal. Sheet metal fabrication transforms raw sheet metal into a variety of finished products. Sheet metal is available in standardized gauges and materials, making it suitable for both mass production and custom products.
Metal fabrication uses complex machinery and manufacturing processes to manufacture high-quality products. Sheet metal typically arrives from a wholesaler or metal mill for a fabrication process that can include cutting, folding, forming, bending, engraving, and more. Standard tools that a metal fabricator will work with include lasers, punch presses, and press brakes.
When high-quality products require clean cuts and no discoloration, a laser cutter will often be used. Intricate patterns are another critical use case for laser cutters. These machines are valued for their ability to handle a wide variety of metals, including carbon steel and titanium.
Metal fabrication involves many different material options, and the proper choice can be critical to project success. For instance, more than 3,500 different grades of steel exist, over 75 percent of which have been developed in the last twenty years. It’s important to partner with an expert fabricator who can guide you through this complex decision.
Product engineers start the process by sending out plans and sketches to different fabricators to get quotes. The fabricators come up with a cost estimate and timeline based on their experience and the potential project.
From these quotes, product engineers select one fabricator for that particular end product. Some end products can have several different fabricators involved in different elements. The fabricator then orders materials for the project, typically sheet metal, bars, rods, and tubes.
Once the parts arrive, the fabricators begin to work. For custom metal fabrication, the fabricators may play a role in the design process, as unique products need specific techniques to achieve the right result. Highly skilled sheet metal shops like All Metals Fabricating can offer excellent guidance on optimal fabrication choices, including design for manufacturing advice to ensure an efficient, cost-effective manufacturing process.
Sheet metal fabrication often integrates with other manufacturing processes, such as precision machining, when specific features require milling or turning. Common machining options include CNC mills and lathes.
The final step of the manufacturing process involves assembly and finishing. These processes prepare the product for use, whether with joining techniques or coatings. Methods like graining with a belt sander or applying a vibratory sanded finish are two raw metal finish options. Other common finishes include powder coating or various plating specifications.
The process of metal fabrication involves a variety of equipment, some of which are unique to metal materials. Here are a few examples of sheet metal services and equipment that can be involved in a project:
Precision sheet metal fabrication is a highly skilled and potentially complex manufacturing process often employed for high-quality products. Below is a short list of essential reasons why metal could be the right choice for your manufacturing project:
The final appearance of your product is critical. Many high-quality manufacturers, such as tech companies, have opted for a metal design. Metal gives smartphones and computers durability and a modern, sleek look.
Your product application demands durability. The durability of metal products is naturally superior to plastic. Notably, metal can withstand higher temperatures. If the manufacturer has taken into account expansion under heat, the heat will usually not damage the product.
Especially in high-volume manufacturing, metal fabrication is far more cost-efficient than other processes. Process replication can reduce the manufacturing cost per unit. Sheet metal fab is also more versatile, allowing for a wider variety of approaches. Options such as contract manufacturing or lights-out manufacturing can further improve a project’s costs, and many shops are investing in automation to increase efficiency.
Precision fabrication is a complex manufacturing technique, but it is highly versatile and adaptable. With the right fabricator, the process can result in a cost-effective, high-quality custom product.
Custom sheet metal fabrication is flexible, as well. Still, some processes will not work with certain materials or may be limited by product design. Therefore, it is crucial to contact a professional metal fabricator for advice and guidance during the design process.
If you’re ready to collaborate with us on your next sheet metal project, request a quote today!
Are you interested in learning more about precision sheet metal fabrication? Contact us today to secure an expert consultation!
Previous: None
If you are interested in sending in a Guest Blogger Submission,welcome to write for us!
All Comments ( 0 )