A guide to sheet metal fabrication processes including cutting bending and other techniques from ndpetrify4's blog

For the production of robust functional parts such as panels, brackets, and enclosures, sheet metal fabrication is an excellent prototyping and manufacturing technique.

Although sheet metal fabrication, in contrast to other manufacturing techniques, is actually made up of a number of different processes, each of which manipulates the sheet metal in a different way. Cutting the sheet metal, shaping it, and joining different pieces of it together are all examples of the various processes that can be used.

A look at the major sheet metal fabrication processes, as well as an explanation of their operation and application are covered in this guide.

What is sheet metal fabrication, and how does it differ from other types of fabrication?

Formalized sheet metal fabrication refers to a collection of manufacturing processes for transforming sheet metal into usable parts. This guide is organized into three categories of processes: cutting, deformation, and assembly. Cutting is the first category, followed by assembly.

Steel, stainless steel, aluminum, zinc, and copper are all common sheet metals, and these materials are typically available in gauges ranging from 0.006 to 0.25 inches (0.015 to 0.635 centimeters) thick. Steel, stainless steel, aluminum, zinc, and copper are also common sheet metals. Thinner gauges are more malleable, whereas thicker gauges may be better suited for heavy-duty parts that will be subjected to a lot of stress in their applications.

Sheet metal fabrication, particularly for partially flat or hollow parts, can be a more cost-effective alternative to processes such as casting and machining. It is also a time-saving procedure that results in minimal material waste.

In general, sheet metal fabrication is used for industrial and consumer parts, and it is also used in specialized industries such as the automotive industry, aerospace, energy, and robotics.

Fabrication of sheet metal: cutting and bending

The act of cutting sheet metal is one of the three primary methods of manipulating it. It can be considered a subtractive manufacturing process (similar to CNC machining) in this context because it allows for the creation of functional parts by simply removing sections of material from a sheet of metal.

A variety of different pieces of machinery, including some that are specifically designed for sheet metal fabrication, can be used by manufacturers to cut sheet metal.

Laser cutting is a popular method for cutting sheet metal, and it is one of the most effective. A laser cutter makes use of a powerful laser that has been magnified by a lens or mirror. A precise and energy-efficient machine suitable for thin or medium gauge sheet metal, it may struggle to penetrate the hardest of materials, such as granite or marble.

Water jet cutting is yet another method of sheet metal fabrication. Water jet cutting is a sheet metal fabrication technique that involves cutting through the metal with a high-pressure jet of water (mixed with an abrasive substance). Water jet cutters are particularly useful for cutting sheet metals with low melting points because they do not generate heat that could cause the metal to deform unnecessarily during the cutting process.

Plasma cutting is the third type of sheet metal cutting available. A plasma cutter works by creating an electrical channel of ionized gas, which then forms a jet of hot plasma that can easily penetrate even thick gauges of sheet metal, according to the manufacturer. Plasma cutters are fast and powerful machines with low setup costs, despite the fact that they are less accurate than laser or water jet cutters.

Although these three cutting machines can be used on a variety of materials other than sheet metal, there are some techniques that are specifically designed for sheet metal fabrication.

For example, the process of punching (also known as piercing) is used to create precise holes in sheet metal by using a punch and die combination. The sheet metal is sandwiched between the two components, and the punch pushes its way through the metal to reach the die at the other end. The circular pieces of removed material that are punched out during the punching process are turned into scrap, but these circular pieces can also be used to create new workpieces, which is referred to as blanking.

When creating a large number of holes, similar equipment to that used for perforating sheet metal can be used.