Novelty Structures is a Turkish metal fabrication manufacturer with experience in Carbon Steel, Stainless Steel and Aluminium components.

What is metal fabrication ?

Metal fabrication is the process of cutting, shaping, and assembling metal materials—such as steel, stainless steel, aluminum, or alloys—into finished products or components.
It involves techniques like cutting, welding, machining, bending, and finishing, tailored to meet specific design and functional requirements.

Metal fabrication worker welding parts

Products

Sheet Metal Fabrication

CNC Machining

Steel Weldments

Stainless Steel Fabrication

Steel Structures

Baseframe & Chassis Fabrication

Contract Manufacturing & Fabrication

Steel Bending Service

Materials & Grades

Carbon Steel

Characteristics:

  • Strong, durable, and relatively inexpensive, suitable for structural applications

  • Prone to rust, so surface preparation and coatings are essential for corrosion resistance.

  • Good weldability, but may require preheating depending on grade.

Fabrication:

  • Cutting is straightforward with laser or oxy-fuel methods

  • Preheating might be required for thicker sections before welding to prevent cracking

  • Moderately easy to form and shape

Grades:

  • European Grades: S235, S275, S355, S690, S700
  • ASTM Grades : A36 , A572, A500,

Stainless Steel

Characteristics:

  • Strong and durable, though varies by grade (e.g., austenitic vs. martensitic), and expensive
  • Several finish options such as polishing and passivation make it ideal for aesthetic and hygienic applications

  • Excellent resistance to rust and oxidation due to chromium content.

Fabrication:

  • Employ TIG welding for precision and to maintain corrosion resistance; avoid contamination from carbon steel tools.
  • Clean and passivate after fabrication to remove contaminants

  • Allow for spring-back when bending

Grades:

  • 304, 310, 316,320
  • 430,439
  • 2205, 2507

Aluminium

Characteristics:

  • Low density makes it ideal for applications where weight and or corrosion resistance is a concern.
  • Relatively soft and ductile, making it prone to scratching or deformation during fabrication.
  • Naturally forms a protective oxide layer, resisting rust.

Fabrication:

  • MIG or TIG welding with proper shielding gas to prevent oxidation.
  • Clean surfaces with tools (dedicated to aluminum) to avoid contamination.

  • Support thin sheets during forming to prevent cracking due to its softness.

Grades:

  • 6060, 6061, 6063, 6081
  • 5005, 5083, 5182, 5754
  • 1050, 2011,7075
Sheet metal contractor

Operations

Laser Cutting

Metal Bending

Welding

Machining

Coating

Cutting

Bending

Welding

Welding is a fabrication process whereby two or more metal parts are fused together by means of heat forming a join as the parts cool. The most common welding method is MIG welding which uses a thin wire as an electrode. The wire heats up as it is fed through the welding instrument and towards the welding site. Shielding gas must be used to protect the weld from contaminants in the air.

Typically, this comes in the form of carbon dioxide, oxygen, argon or helium. MIG/MAG welding processes are very versatile and can be used in a range of sectors, including the metalworking industry, shipbuilding, steel and container construction, and the automotive industry. . MIG welding is particularly suited to the non-ferrous metals; aluminium, magnesium, copper, and titanium. MAG welding is usually used to weld unalloyed, low-alloy, and high-alloy steels.

Machining

Machining is a process in which a metal is cut to a desired final shape and size by a controlled material-removal process. Three principal machining processes are categorized as turning, drilling and milling. Other operations classified under miscellaneous categories are shaping, planing, boring, broaching and sawing.

Novelty Structures supplies machining services under several categories.

Painting

Painting plays an important role in finishing metal parts, products, and components. Painting custom metal fabrication is done for many reasons, such as providing colour or identifying a brand. However, painting also supplies a protective finish to fabricated metal surfaces.

Metal surface painting forms a solid barrier to remove contact between chemical compounds or corrosive materials. Metal paints may come in a liquid, paste, or powder and are applied through various methods. Wet paint is applied through spray or pump, whereas powder is applied through an electrostatic plating process. Once the paint hardens, it creates a protective skin on the custom metal fabrication that sticks to metal and protects it from corrosion.

Major challenges

Quality Control Issues

Description

  • Defects like inaccurate cuts, out of tolerance dimensions

  • Weld imperfections (e.g., porosity, cracks)
  • Surface blemishes

Impact

  • Requires rework
  • Increases costs
  • Delays delivery

          How we cope ?

  • Implement quality management systems and QC unit
  • Provide sample fabrication to identify potential defects before serial production.

  • Train staff and use CNC machinery for accuracy and speed.

Material Delays

Description

  • Late deliveries of raw materials due to inconsistent supplier lead times.
  • Unavailability of special grades

Impact

  • Halts production
  • Forces timeline adjustments or material substitutions.

          How we cope ?

  • Build relationships with reliable suppliers
  • Maintain buffer Inventory
  • Early plan of procurement
  • Engage multiple suppliers for every stock

Communication Gaps

Description

  • Miscommunication between shop floor, sales and the client.

  • Lack of technical expertise of the sales people

Impact

  • Causes missed deadlines, rework, and customer dissatisfaction.

          How we cope ?

  • Improve handoff processes
  • Use clear documentation
  • Employ trained staff
  • Promote close communication within organisation parties

Metal Fabrication Costs and Pricing

Material Costs


  • Raw Materials: The price starts with the cost of metal (e.g., steel, aluminum, stainless) based on current market rates, which fluctuate. We calculate the amount needed adding a buffer of 10-15% for wastage.

  • Consumables:Welding wire, gases (like argon or oxygen), cutting fluids, abrasives, and fasteners are factored in. These are smaller costs but add up, especially for complex jobs.

how do we price metal fabrication work

Maching & Tooling Costs


  • Equipment Usage: We calculate the cost of running machines (e.g., CNC machines, laser cutters, press brakes) based on depreciation, maintenance, and energy use.

  • Special Tooling: If a job requires custom dies, jigs, or fixtures, that cost is added—either amortized over the project or charged upfront if it’s a one-off.

Labour Costs


  • Time Estimate: We estimate how many hours the job will take, breaking it down by process—design, cutting, welding, assembly, finishing, etc.

  • Hourly Rate: This varies by the process related operator. General expenses are also factored in this rates.

  • Skill Level: Complex jobs needing experience and craftmanship might bump up the rate.

Overhead


  • Fixed Costs: Rent, utilities, insurance, and administrative salaries are spread across all jobs.We often roll this into their hourly labor or machine rates (e.g., adding 20-30% to direct costs).

  • Variable Costs: Things like shop supplies or waste disposal might scale with the job’s size.

Complexity and Design


  • Engineering Time: If we need to interpret vague sketches, create detailed drawings, or modify the design, we might charge for design time.
  • Difficulty: Tight tolerances, intricate shapes, or exotic materials (e.g., titanium) increase the price due to higher skill, slower production, or risk of errors.

Quantity and Scale


  • Economies of Scale: Larger batches reduce the per-unit cost since setup time (e.g., programming a CNC machine) is spread out. A prototype might cost significantly higher than serial production.
  • Setup Fees: Small runs or one-offs might include a setup charge to cover initial machine adjustments or material prep.

Finishing and Add-Ons


  • Surface Treatment: Powder coating, painting, galvanizing, or polishing adds cost based on labor, materials, or outsourcing fees.
  • Assembly: If the job includes bolting, riveting, or fitting parts together, that’s extra time and effort.
  • Packaging/Shipping: Custom crates or delivery charges might be tacked on, especially for heavy or fragile items.
Stainless Steel Welding Fabrication

How can we help you ?

Novelty Structures is an experienced metal fabricator with a diversified range of processing operations.

Contact our team to discuss your projects.