Sheet metal fabrication is the backbone of modern manufacturing. Without it, we wouldn’t be able to create the parts we need to keep our cars, homes, computers and businesses running. But what is metal fabrication and how does it work? Read on to find out more about sheet metal fabrication, the types of processes involved and the industries that rely on it.
Are you looking for a metal fabrication company in Wiltshire or the surrounding area? Give us a call to find out more about our metal fabrication services and request a free quote.
What’s on this page
- What is metal fabrication?
- How does the custom metal fabrication process work?
- Types of sheet metal fabrication processes
- Industries that use sheet metal fabrication
- Why should you outsource your sheet metal fabrication requirements?
- Metal fabrication services in Wiltshire
What is metal fabrication?
Before we look at the metal fabrication process in more detail, let’s go back to the basics and answer the key question – what is metal fabrication?
Put simply, metal fabrication is the process of manipulating sheet metal into a specific shape to form a desired part or structure. This usually involves a variety of manufacturing techniques such as cutting, punching, machining, bending and welding (more on this below).
Sheet metal itself is relatively thin, typically ranging between 0.5mm and 6mm thick, and comes in various types. Custom metal fabrication companies like us work with a range of different metals, although the most common include steel, stainless steel, aluminium, copper and brass.
As for the final product, this can be anything from a small bracket or valve to large steel structures and support pilings. In fact, many of the items you use on a daily basis will have gone through the metal fabrication process or include a metal-fabricated component.
An example of small metal-fabricated components for the automotive sector
How does the custom metal fabrication process work?
Metal fabrication can be broadly divided into the following stages: design and prototyping; cutting; bending; assembly; and finally finishing (if required). While some companies focus on one element of the metal fabrication process eg cutting, we provide a complete end-to-end solution that’s designed to save you time and money.
In this first crucial phase, engineers will use CAD software to design your required component or structure. As part of this process, they’ll produce a 2D or 3D technical drawing to suit your specific measurements, angles and tolerances.
One of the many benefits of using CAD software (in our case, Solidworks), is that it enables us to identify flaws before production begins. At Knees Engineering, our team will work closely with you during this initial stage to troubleshoot potential problems and refine the design. Once you’re happy, we can then create a prototype for your approval.
During this crucial stage, a piece of sheet metal is cut into the desired shape using one of several cutting techniques. Laser cutting is by far the most popular cutting method used today because it offers precision, excellent cut edge quality and is exceptionally fast. Other common cutting techniques include waterjet cutting and plasma cutting. Depending on your project’s specifications, your part may also undergo CNC punching – a process in which turrets ‘punch’ pre-designed holes or 3D forms into the metal.
Once the sheet metal has been cut to the required size and shape, it’s then manipulated and reshaped into the desired form using a tool known as a press brake. There are several ways to bend metal on a press brake. The exact technique used will depend on factors such as the type of metal and the angle of the bend.
A press brake is used to bend sheet metal to the required angle
- Assembly
Depending on your requirements, the cut and bent pieces of metal may then be joined together. Known as assembly, this stage often involves using welding techniques to fuse the parts. There are various types of welding methods, including MIG, TIG, stud and spot welding. An experienced welder will be able to choose the most suitable technique for your project.
- Finishing (if required)
Following the assembly phase, the metal part or structure may then go through a finishing phase. Although finishing is not strictly part of the metal fabrication process (it’s a secondary phase designed to treat the exterior), it’s still a crucial step in the journey of many custom metalwork projects.
Finishing can cover a variety of services such as deburring, polishing, powder coating, spray painting, anodising, galvanising and more. Again, the most appropriate finishing technique will depend on the specific material and the intended purpose of the end part.
If your product does require a specific type of finish, we can call on our trusted network of external specialists to perform a range of processes. Explore our finishing services for more information or get in touch to speak to our experienced Wiltshire-based team today.
Types of sheet metal fabrication processes
As you’ve probably gathered, sheet metal fabrication encompasses a myriad of different processes. Below we summarise some of the most common techniques you might encounter, although this will of course depend on your project’s specific requirements.
- Laser cutting – As the name suggests, laser cutting uses a fine laser beam to slice through or engrave a material. It’s capable of producing exceptionally precise cuts and high-quality finished edges.
A laser cutter can cut complex shapes with great precision
- Waterjet cutting – Another common cutting technique in which a highly pressurised abrasive water jet slices through metal and other materials.
- Shearing – A metal fabrication process in which a blade is used to trim unwanted material from a flat piece of metal.
- Punching – This involves the use of a machine known as a punch press, which cuts holes into a piece of sheet metal. The technique can be used to create a variety of shapes, from basic circles to overlapping geometric 3D designs, as well as metal forms such as louvres and dimples.
- Stamping – A similar process to punching, stamping is used to make indentations (eg shapes, letters and images) rather than holes.
- Machining – Often controlled by CNC technology, machining is the process of removing unwanted material from a metal part. Common machining techniques include drilling, turning and milling.
- Casting – Molten metal is poured into a mould, before being left to cool and harden. The mould can then be reused to create identical parts, making it ideal for batch jobs.
- Bending and forming – A press brake machine is used to bend, fold and press sheet metal into the required angle or shape. You might also hear it referred to as folding or press braking.
- Welding – A process in which two materials (usually metals) are joined together using extreme heat. The parts are melted (fused) together and, once cooled, the joints harden to create a final fabricated structure.
Industries that use sheet metal fabrication
From automotive to agriculture, countless industries rely on sheet metal fabrication to manufacture a variety of parts and products. Here’s a selection of some of the key sectors but there are many more.
- Agriculture – examples of metal-fabricated products include livestock equipment, tractor parts and fencing brackets.
- Oil and gas – pipelines, breakaway couplings and oil rigs are all made using metal fabrication techniques
- Construction – from steel support pilings and structural beams to staircases and railings, the construction sector is heavily reliant on metal fabrication
- Automotive – examples of metal parts include gaskets, brackets, manifold housing and exhaust parts
- Architectural and property – metal gates, staircases, arbours and bespoke metal art will have all undergone some type of metal fabrication process
Metal fabrication has a wide range of applications, including staircases
- Medical – examples of medical metal-fabricated parts include surgical instruments, bedframes, prosthetics and metal components in implant devices
- Aerospace – metal fabrication is essential to the aerospace industry, with aircrafts relying on various flight-critical, precision-machined metal components
- Food processing – metal fabrication processes are used to create a range of parts for food processing equipment
- Telecommunications – telecommunication equipment and storage cabinets are made using common metal fabrication techniques
- Seating solutions – metal seating structures are used in a wide range of public venues including football stadiums, theatres and lecture halls
These are just a handful of the industries that use sheet metal fabrication. In reality, virtually any bespoke metal product can be created to suit your business’s needs – whatever sector you’re in. Read more about the industries we work with.
Why should you outsource your sheet metal fabrication requirements?
While some businesses have facilities to handle their metal fabrication in-house, many will need to use an external metal fabricator to fulfil their requirements. The good news is that there are many benefits to outsourcing your metal fabrication to a third party, a few of which are outlined below.
- Cost savings – Metal fabrication requires a huge capital investment, not to mention a highly skilled workforce. Outsourcing your metal needs to a third party will therefore save you a substantial amount of money on expensive machinery and personnel costs.
- Access to the latest technology – Working with an experienced metal fabricator means your project will benefit from a wider range of innovative technologies and cutting-edge machinery. Outsourcing your metal fabrication enables you to utilise this technology and maximise quality while keeping expenses to a minimum.
- Skilled labour – Using an established metal fabrication company also means you’ll benefit from a wealth of specialist knowledge and experience. Companies like ours employ highly-trained engineers, many of whom have spent years honing their skills. Having access to this level of expertise can be especially useful if you have an unusual or particularly challenging project.
- High-quality results – Thanks to this combination of advanced skills, experience and state-of-the-art technology, you can be confident that your project will be finished to the highest possible standards.
Metal fabrication services in Wiltshire and beyond
We can handle the entire manufacturing process on your behalf, from design and prototype through to fabrication and final finish. Many of our customers find this saves them the inconvenience and expense of having to contract with different providers to manage their requirements.
We also invest heavily in our equipment and our dedicated workshop boasts modern metal fabricating technology, software and machinery. This enables us to provide you with the very best quality and results.
What’s more, every job goes through our stringent quality assurance procedures to ensure it is manufactured to a high standard and meets your specifications and brief exactly.
Our factory is based in Trowbridge, Wiltshire, but we work with businesses from across the UK.
Explore our range of metal fabrication services here or send us your project details and we’ll be happy to provide you with a free, no-obligation quote.