Metal fabrication is the process of shaping and assembling metal – transforming it from a raw material into usable components. There are many different types of metal fabrication techniques used by manufacturers from welding to press braking. If you’ve been thinking of getting into metalwork or are looking at ways to manufacture a metal product, this guide to some of the different fabrication methods could be worth a read.
Welding
Let’s begin one of the most well-known metal fabrication methods: welding. This is a process used to join two or more pieces together by heating them to melting point and then fusing them. Welding creates strong joints that can withstand substantial loads. Due to being quite hazardous work that is often done manually, skilled laborers need to be hired to carry out this fabrication method. Various welding techniques exist including MIG (metal inert gas) and TIG (tungsten inert gas). A wide array of industries use welding including construction, aerospace and the automotive industry.
Laser cutting
When it comes to cutting metal, laser cutting has become a common manufacturing method due to its high precision and lack of wastage. It involves using a focused laser beam to cut through materials like steel, aluminium and brass. Laser cutting machines are often computer programmed and are able to take intricate digital designs and quickly cut them into shape. It’s an excellent fabrication method for prototypes and complex parts. Make sure to find the right nitrogen supplier to improve cut quality.
Plasma cutting
Need to cut through thicker metal? Plasma cutting uses a high velocity jet of superheated gas to cut through sheets up to several inches thick. Like laser cutting, it can be used to cut fairly complex parts speedily. It’s commonly used in industries like construction and shipbuilding when fabricating large parts. Nitrogen is also typically used for precise work, while compressed air is a popular choice for those looking to reduce costs.
Water jet cutting
If you want to cut through materials without generating heat, an alternative cutting method to look into is water jet cutting. This involves using a high pressure jet of water to make precise cuts in sheets of metal. Many manufactures choose water jet cutting for the smooth edges it leaves, however it’s worth mentioning that this fabrication method can be quite slow and expensive compared to other cutting methods. When using tap water as a water supply, consider using a water softener to protect high-pressure components.
Sawing
This is an old-skool metal fabrication method that involves cutting metal with a saw. While this can include hand saw, most metal sawing today is done using machines like band saws and circular saws. It’s a relatively inexpensive method of cutting bars, sheets and tubes into shape. The downside is that it can sometimes require secondary processing to smooth down cut lines. Metal saw machines often use tungsten carbide tipped blades, while bi-metal may be used for thicker sheets. For those opening a low-scale workshop on a tight budget, metal sawing could be the best form of cutting to look into.
Punching
Punching is a method of creating holes in metal sheets. It can be used to create decorative patterns like cutout lettering or more functional features like grills and vents. Many large scale manufacturers automate the punching process, however it’s possible to set up manual systems with punch and die sets for smaller batches or custom products. Because punching creates a lot of waste, it’s important to find a way of recycling this where possible. Many factories sell this waste to a scrap metal company to be molten down and reused in other components.
Stamping
Whereas punching is used for holes and cutouts, stamping is used to create textured 3D forms. This can include embossed logos, heat sinks or inlets. It’s a fabrication method used to manufacture all kinds of components from automotive body panels to household appliances. Like punching, stamping can be automated for use on large production runs, or you can set up your own manual press for small batches (hydraulic stamping machines tend to still be best for thicker materials and consistency).
Rolling
When it comes to shaping material into curves, rolling is the perfect solution. This fabrication process can also be used to reduce the thickness and increase the width of sheets. There are two main types of rolling: hot rolling and cold rolling. Hot rolling is often used for rougher structural components like structural steel, whereas cold rolling is often used for smaller precise parts when enhancing strength and surface finish is the main goal. It’s possible to use rolling on a range of metal types for high volume orders.
Panel bending
Panel bending is a metal fabrication technique that involves bending metal sheets into specific shapes using a bending machine. It’s useful for producing enclosures, housing and other items with multiple bends. This fabrication method is typically used on thinner metals and used for high volume orders. It can provide highly accurate results and requires minimal setup time, but can cost quite a bit to set up.
Press braking
This is another method of bending metal. Unlike panel bending, press braking is typically carried out manually by skilled operators. It has the advantage over panel bending in that it can be used to bend metals of varying thicknesses. It’s not as fast as automated panel bending, however precise adjustments can be made. When fabricating thicker metals, make sure to use a hydraulic press brake with high tonnage capacity.
Final thoughts
These are just some of the main metal fabrication techniques – there are many more options out there for machining various specialist parts including metal finishing techniques. When choosing the right fabrication method, think carefully about your budget, the size of the batches you are creating, the level of customization you require and the quality you want to achieve. Some metal fabrication techniques can be automated, but others must be carried out manually (or are much more economical to carry out manually).
