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Because thin sheets of metal are more malleable than a thick workpiece, they can be manipulated using different processes.
These processes fall into three general categories:
Laser cutting is a precise and efficient method used in sheet metal fabrication. It focuses a high-powered laser beam—typically around 0.001″ (0.025 mm) in diameter—onto the material to produce clean, accurate cuts.
With focal lengths between 1.5″–3″ (38–76 mm), it delivers tight tolerances (up to ±0.002″ / 0.05 mm) and narrow kerf widths (0.006″–0.015″ / 0.15–0.38 mm). Laser cutting is ideal for complex shapes and fine details, though it may not be suitable for very thick metals.
Advantages: high precision, minimal finishing, and broad material compatibility.
Water jet cutting uses a high-pressure stream of water—often mixed with abrasive material—to cut through sheet metal. This method is especially effective for thicker materials.
Unlike laser or plasma cutting, water jet cutting is a cold-cutting process that produces no heat-affected zone (HAZ). It’s ideal for metals with low melting points or materials that require no thermal distortion.
Typical part accuracy reaches ±0.002″ (0.05 mm), with kerf widths between 0.006″–0.015″ (0.15–0.38 mm). It also supports a wide range of materials without altering their properties.
Advantages: no thermal damage, high precision, material flexibility.
Plasma cutting uses a high-temperature plasma arc to cut through sheet metal. It forms an electrical channel of superheated ionized gas, enabling fast, efficient cuts with relatively low setup costs.
Ideal for thick materials—up to 6″ (150 mm)—plasma cutting is more powerful than laser or water jet systems, though typically less precise. Computer-controlled machines handle cuts up to 0.25″ (6.35 mm) thick with ease.
Part accuracy is around ±0.008″ (0.2 mm), and cutting speeds can reach 200″ (5.08 m) per minute on 16-gauge mild steel.
Advantages: high cutting speed, low cost, great for thick metals.
Punching is a fast and cost-effective method for creating holes or cutouts in sheet metal. The process sandwiches the sheet between a punch and die—when the punch drives into the die, it shears a hole through the material.
It’s especially efficient for repetitive hole patterns or irregular shapes, which can be formed by a series of small, closely spaced punches.
Punching works well with most sheet metals, but hole diameters should generally exceed the sheet thickness for optimal accuracy and edge quality.
Advantages: high-speed production, low tooling cost, ideal for perforated designs.
Bending is a forming process to shape sheet metal into V-, U-, or channel profiles using a press brake. The metal is clamped and pressed to a specific angle, typically up to 120°, depending on its thickness and tensile strength.
Due to material elasticity, sheet metal is often over-bent to compensate for springback, ensuring the final angle meets design requirements.
Bending is ideal for creating enclosures, brackets, and structural components with precise angles and repeatability.
Advantages: cost-efficient forming, high repeatability, compatible with various metals.
Stamping is a high-speed forming process that uses a mechanical or hydraulic die to press sheet metal into a desired shape. It’s commonly performed on cold sheet metal, though friction during the process generates localized heat.
Stamping enables a wide range of part features through sub-processes such as:
Ideal for high-volume production, stamping ensures consistent shapes with tight tolerances.
Advantages: fast cycle time, precise detail, excellent for mass production.
Spinning is a metal forming process used to produce hollow, symmetrical parts with smooth, rounded features—similar in concept to pottery wheel forming.
In this process, a sheet metal blank is rotated on a lathe and pressed against a shaped tool, forming the material into its final contour. Spinning can be done manually or mechanically, depending on complexity and volume.
Common shapes include hemispheres, cones, and cylinders, making spinning ideal for components like reflectors, nozzles, and decorative parts.
Advantages: smooth finishes, low tooling cost, ideal for rounded geometries.
Assembly is the final stage of sheet metal fabrication, where multiple parts are joined to form a complete product. Components can be connected using fasteners, welds, rivets, or other standard joining methods.
This process typically follows any required cutting, forming, and surface finishing, ensuring all parts are ready for integration.
Assembly is essential for creating functional structures such as enclosures, frames, and mechanical housings, especially in complex or multi-part designs.
Advantages: product readiness, design flexibility, supports both manual and automated methods.
Welding is a joining process that fuses sheet metal parts using high heat, creating a strong, permanent bond between components. It is commonly used in structural and enclosure applications.
Materials like aluminum and stainless steel offer excellent weldability, making them ideal for sheet metal welding. The specific technique—such as TIG, MIG, or spot welding—depends on the material type, thickness, and application.
Welding is typically performed after forming and before finishing, ensuring structural integrity and seamless assembly.
Advantages: strong joints, permanent bonding, compatible with various metals.
Choosing the right manufacturing method is key to achieving the desired part quality. Not sure which method suits your needs?
High-quality sheet metal materials such as aluminum, stainless steel, and brass are available, ensuring consistent quality and reliable performance across all parts.
Choose an appropriate finish to enhance the durability and appearance of your custom metal parts. If you have specific needs, feel free to let us know what you're looking for.
Follow specific design rules to ensure manufacturability, structural integrity, and cost-efficiency for sheet metal parts.
Sheet metal fabrication is the process of forming flat metal sheets into custom shapes and structures using techniques such as cutting, bending, and assembly. This involves various tools and machinery to manipulate the sheets, producing products like enclosures, brackets, and other metal components.
For end-use applications, additional finishing processes like powder coating, plating, or anodizing are often required to enhance durability and appearance.
Sheet metal fabrication involves cutting, bending, and assembling metal sheets into specific shapes and sizes. The process starts with cutting the sheet to the desired size, followed by shaping it using bending or punching. Afterward, components are welded or fastened together, and finishing processes like painting or coating may be applied.
Sheet metal is generally cheaper than CNC machining for mass production due to lower material and tooling costs. However, CNC offers greater precision and design flexibility, making it more suitable for complex parts. The cost difference depends on the project size and complexity.
The type of cutting machine used depends on the chosen material and the gauge of the sheet, as well as factors like desired lead time and tolerances.
We know which projects need which equipment, so you don’t need to specify a particular cutting machine.
