Although it may be something you never think about, metals like steel and aluminium are a huge part of our lives whether you realise it or not. It is known to be everywhere, especially with modernised designs including a more metallic look.

However, metal is formed in many different shapes and sizes. How is this possible? Do machines control it or are there different techniques? The metal fabrication process is the cause of all this, but what tools and processes are used/taken? Read on to learn more!

 

What is Metal Fabrication?

As we’ve briefly discussed, metal fabrication is the act of creating structures from raw metal. This can be any form of metal, such as aluminium, steel, etc. Any type of metal, including the ones on that list, can be shaped in many versatile ways using many different methods.

Common metal fabrication methods will begin well before the production stage, hiring the right metal fabrication services or using the right metal fabrication shop to get the best results for the client.

Not only that but due to the high risk and parts being extremely expensive and solid – each project must be put through policy (or given a quote) to make sure the health and safety actions are on point!

 

Popular Metal Fabrication Techniques

When it comes to metal fabrication processes, there are a multitude of ways to structure and shape your metal. From custom metal fabrication to essential (set in stone) sheet metal fabrication, you will find many different methods.

Each of these techniques plays a crucial role in metal fabrication, often being used in combination to produce complex parts and components for various industries. The choice of technique depends on factors like material properties, desired shape, production volume, and cost considerations.

Here are the most common processes in the industry that you will often see:

 

Cutting

Due to the several amounts of machinery that can be used for general metal fabrication, such as waterjet cutting, laser cutting, plasma cutting, etc – the flexibility of this method is unmatched.

Although it is extremely adaptable, there is still a high level of delicacy and precise cutting that goes into this process. Therefore, making sure qualified staff are hired for the job is necessary.

Typically, cutting will come before other metal fabrication methods as they often begin the project by cutting these large pieces of metal into smaller pieces and or shapes.

 

Welding

Either after cutting, or using two large pieces of metal – the welding process for a certain design can be used. Welding is the procedure of joining two (or more) pieces of metal together via heat and or pressure.

For this operation, high-tech machinery is needed as said project may need a very particular shape using these materials. Here are some of the benefits of welding:

  • Creates strong, permanent joints
  • Suitable for a wide range of metals and alloys
  • Can be automated for high-volume production
  • Allows for complex shapes and designs
  • Cost-effective for many applications

 

Machining

Machining typically has two uses when it comes to a successful metal fabrication process. Firstly, you may use a practical method, such as creating the wanted texture or looking for the finishing touches of your intended model.

Or, in the production phase of the scheduled design, you may notice that you need to dispose of a certain material or shape. Using machining permits you to use either milling, drilling or turning to remove a mistake in your conscious plan.

From here, it goes hand in hand with welding as you can use their moulding features to reinvent and fix the mistake that was made.

 

Shearing

Shearing is a cutting process that uses two blades to slice through sheet metal. Shearing typically involves:

  • Use of a stationary lower blade and a moving upper blade
  • Applying shear force to cut metal along a straight line
  • Suitable for cutting large sheets or plates of metal
  • Producing clean, burr-free cuts when properly executed
  • Often used as an initial step to cut metal to size before further processing

 

Stamping

Stamping is a forming process that shapes flat sheet metal into three-dimensional parts. Key aspects of stamping are:

  • Uses a die and punch to form the metal
  • Can create complex shapes and features in a single operation
  • Suitable for high-volume production
  • Types include progressive stamping, transfer stamping, and deep drawing
  • Commonly used in automotive, appliance, and electronics industries

 

Punching

Punching is a process that creates holes or shapes in sheet metal by shearing. Important points about punching include:

  • Uses a punch tool to force the material through a die
  • Can create various hole shapes and sizes depending on the punch and die used
  • Often automated for high-volume production
  • Suitable for creating holes, slots, and other cutouts in sheet metal
  • Can also form features like louvres and embossing

 

Bending

Bending is a forming process that creates angles in sheet metal. Here is some information worth noting about bending in metal fabrication:

  • Uses a punch and die to apply force and create an angle
  • Common types include air bending, bottoming, and coining
  • Can create various bend angles and profiles
  • Often used in conjunction with other fabrication processes
  • Requires consideration of material properties to avoid cracking or spring back