Bended Sheet Metal Parts

Sheet Metal Fabrication Services for

Carbon, Galvanized, Stainless Steel and Aluminium

Contents

 

 

Sheet metal fabrication is the process of turning flat sheets of metal into desired shapes and structures using a variety of techniques, including cutting, bending, and welding. The metals commonly used in this process are mild steel, galvanized steel, stainless steel, aluminium, copper, and brass.

Sheet Metal Laser Cutting Part

Sheet Metal Fabrication Steps

  Cutting

Laser Cutting

  • Precision: Tolerances as tight as ±0.1mm.

  • Application: Best for intricate designs and thin sheets.

Plasma Cutting

  • Precision: Tolerances around ±0.5mm.

  • Application: Used for thicker metals (up to 50mm).

Water Jet Cutting

  • Advantage: Heat-free process eliminates thermal distortion.

  • Application: Suitable for a wide range of materials, including composites.

Sheet Metal Laser Cutting

CNC Punching

  • Advantage: High-speed, repeatable perforations or patterns.

  • Limitations: Restricted to standard tool shapes.

Sheet Metal Punching

  Forming

Press Brake Bending

  • Commonly used for angular bends of the sheet metal.

  • Accuracy depends on material elasticity and tooling setup.
sheet metal fabrication - bending
Roll Forming
  • Suited for continuous profiles like channels or tubes.
  • Requires precise alignment to avoid material deformation.
sheet metal plate rolling
Deep Drawing
  • Converts flat sheets into cylindrical or box-shaped parts.
  • Engineering considerations include material ductility and strain hardening.
sheet metal deep drawing

  Welding

Tig Welding

  • Offers clean welds with minimal spatter for sheet metals.

  • Suitable for thin metals and precision applications.
Sheet Metal Tig Welding
Mig Welding
  • Provides high deposition rates for thicker materials.
  • Less suited for detailed work due to greater heat input.
Mig Welding Sheet Metal Fabrication
Spot Welding
  • Ideal for joining overlapping sheets in high-production environments.
  • Requires careful control of current and pressure to ensure weld strength.
Spot welding of sheet metal
For more information, please check our Welding Methods page.
Surface Finishing
  • Grinding: Smoothing edges and removing imperfections.
  • Polishing: Creating a shiny or smooth finish.
  • Painting: Applying protective or aesthetic coatings.
  • Powder Coating: Adding a durable and even finish using heat-cured powder.
  • Anodizing: Protecting aluminium sheets with an oxidized layer.
  • Plating: Coating the sheet with another metal, like zinc or chrome.
Sheet Metal Powder Coating
For more information, please check our Stainless Steel Surface Preparation page.

Quality Control

Stages Key Actions Tools/Techniques Objective
1. Initial Material Inspection
  • Check material grade, thickness, and surface condition.
  • Verify certifications and standards compliance.
  • Visual inspection
  • Thickness gauges
  • Ensure raw materials meet project specifications and are free from defects.
2. Cutting Accuracy
  • Verify dimensions and edges after cutting.
  • Inspect for roughness or thermal distortion.
  • Laser/plasma cutting systems
  • Calipers
  • Edge quality inspection tools
  • Ensure precise cutting and maintain design accuracy.
3. Forming and Bending
  • Check angles and bends for accuracy.
  • Account for spring back in metals.
  • Angle gauges
  • Templates or fixtures
  • CNC press brake monitoring
  • Ensure bends align with specifications and avoid misalignment.
4. Welding Inspection
  • Inspect weld seams for cracks, porosity, or spatter.
  • Ensure joint strength and integrity.
  • Visual inspection
  • Dye penetrant testing
  • Ultrasonic or X-ray testing
  • Guarantee welds are strong and free of defects.

5. Dimensional Verification

 
  • Measure dimensions, angles, and tolerances.
  • Verify part alignment and fit.
  • Coordinate Measuring Machines (CMM)
  • Calipers, micro meters
  • Jig or fixture checks
  • Confirm the fabricated part matches design specifications.
6. Surface Finish Inspection
  • Inspect for uniformity of coatings and finishes.
  • Check for scratches, bubbles, or corrosion.
  • Visual inspection
  • Roughness testers (profilometers)
  • Coating thickness gauges
  • Ensure consistent surface quality and protect against corrosion.
7. Functional Testing
  • Test components for load-bearing and stress resistance.
  • Verify fit in assemblies.
  • Stress/load testing rigs
  • Assembly mock-ups
  • Confirm that the part performs as required in its intended application.

Materials used in Sheet Metal Fabrication

Carbon Steel

  • Strong and affordable, used in general-purpose applications
  • Prone to rust without coating.

Stainless Steel

  • Corrosion-resistant and durable
  • Common in food, medical, and outdoor industries.

Galvanized Steel

  • Steel coated with zinc to resist rust
  • Used in roofing, ductwork, and automotive parts.

Aluminium

  • Lightweight, corrosion-resistant, and easy to work with
  • Popular in aerospace, automotive, and electronics.

Copper

  • Excellent electrical and thermal conductor
  • Used in wiring, roofing, and decorative applications.
Sheet Metal Fabrication Bending

Brass

  • A copper-zinc alloy with good corrosion resistance
  • Used in decorative parts and plumbing fittings.
Sheet Metal Laser Cutting

Automation in Sheet Metal Fabrication

Process Role of Automation Technology
Cutting Automated laser, plasma, or waterjet cutting with precise control of speed and pattern. Fiber laser cutting machines, CNC plasma cutters.
Bending Robots load/unload materials into CNC press brakes, Precise bending and automatic machine setup 3 axis CNC Press brakes
Robotic Press Brake Cells
Punching Automated turret punching systems allow for faster, more efficient punching and forming operations. CNC turret punch integrated with press brakes
Welding
 Robotic welding arms improve speed and ensure uniform welds for large or repetitive jobs. CNC-controlled robotic welders.
Assembly Automated robotic systems assemble components post-fabrication. Robotic assembly arms.
Inspection Vision and sensor systems detect defects, measure tolerances, and verify quality. Sensors and laser scanners integrated into the machines

Challanges

Sheet metal fabrication offers many benefits, but it also presents a range of challenges. Here are some of the key challenges in sheet metal fabrication:

  • Precision and Tolerances: Achieving accurate measurements for complex shapes can lead to fitting issues.

  • Material Waste: Cutting and shaping often cause material waste, increasing costs and environmental impact.

  • Bending Issues: Bending can cause distortion or cracking, especially with thicker or brittle materials.

  • Tool Wear and Maintenance: Tools wear out over time, affecting quality and causing downtime for repairs.

  • Complex Designs: Complex designs need advanced machinery and more time, increasing costs and errors.

  • Heat Distortion from Welding: Welding heat can warp or weaken the metal, affecting strength and quality.

  • Material Shortages: Delays or shortages in raw materials can disrupt production schedules and raise costs.

  • Cost Management: Balancing high-quality fabrication with affordable pricing, especially for custom parts.

  • Skilled Labor Needs: Requires skilled workers to operate sophisticated machinery

  • Custom Parts and Prototypes: Custom parts and prototypes are more time-consuming and expensive to make.

Sheet metal contractor

How to find the Right Sheet Metal Fabricator ?

  • Clear and responsive communication.
  • Experience and expertise in your industry.
  • Quality standards and certifications (e.g., ISO).
  • Up-to-date technology and equipment.
  • Realistic lead times and project flexibility.
  • Competitive and transparent pricing.
  • Full capabilities and scalability for your project.
  • Positive reviews and good reputation.
  • Location and accessibility for convenience.

How can we help you ?

Novelty Steel has a proven track record of delivering successful metal fabrications based on client requirements. Our deep understanding of mild

steel, aluminium and stainless steel and their unique forming characteristics enables us to meet necessary quality criteria.

We offer bespoke customer experience based on the characteristics of the job; from sample fabrications to mass production.

Contact our team to further discuss your needs.

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