Sheet metal fabrication transforms raw materials like steel, aluminum, and copper into working elements. Fabricators use techniques such as cutting, forming, and welding to create custom metal pieces for various uses. These metal parts are sturdy, durable, and versatile, and they can be made to look premium through processes like galvanizing and powder coating. In addition, they can withstand harsh environments and heavy usage.
The Role of Sheet Metal Fabricators
Sheet metal fabrication is a process that turns raw metal stock into functional components and structures. It can be performed on a large scale for mass production or on a smaller scale with custom projects, including the creation of residential, commercial, and industrial products. Some major processes involved in sheet metal fabrication are cutting, bending, and deformation.
Cutting typically uses a machine to cut out 2D geometric shapes or holes in the sheet metal. Bending can be accomplished by a variety of methods, such as hemming, which involves folding a piece of metal over itself, or by using a press brake to bend the sheet. Deformation can involve stretching or a more unique process like metal spinning, which produces axially symmetrical parts.
Tools and Equipment
The work of sheet metal fabrication requires advanced machinery to perform complex tasks that are nearly impossible to do by hand. Using machines and advanced technology allows for more production and better results. Brakes and bending machines fold and crease flat sheets, angles, bars, and tubes. They also can create curves, rolls, beads, and other profile shapes on these materials.
Shearing machines: leave clean-edged cuts on sheet metal or struts and rods.
Punching and notch tools: Create notches, holes, or other profiles in these workpieces.
Shaping machines: Smooth, curved, or stretch sheet metal and are commonly used to form domed workpieces.
Ironworkers and combination machines are multi-station units that perform multiple metal-forming functions simultaneously. It is hard to imagine a modern industrial or residential building without architectural metal works. From stainless steel staircases to window frames and roof structures, metal can give buildings and other properties a stylish and durable look. It can also add a modern or traditional touch to interior designs and provide structural stability. These types of designs are best done by professionals who have the right equipment and knowledge.
Materials Used
The type of material that sheet metal fabricators use is largely determined by what the end product needs to be made of. Typical materials include aluminum, copper, brass, steel, and tin. These can be cut and formed to make a variety of end products, from household fixtures like mailboxes and roof gutters to industrial components like phone casings and air-conditioning ducts or furnace flues. There are several different types of forming and cutting processes that are used by sheet metal fabrication shops.
- Some of these are categorized as shear and non-shear.
- Shear cutting, which is similar to the way scissors work, uses upper and lower blades to cut a piece of sheet metal.
- Non-shear cutting, on the other hand, is more precise and is often used for industrial products like airplane wings.
- There are also deformation processes that sit somewhere between shear and cutting, such as punching, which uses a metal punch to create shaped holes in the sheet.
Other deformation processes that sit closer to cutting include spinning. Which looks a lot like pottery spinning and is useful for creating rounded parts such as cones and cylinders.
Architectural Applications
Sheet metal fabrication can be used to create a variety of different products for a wide range of industries. It can be cut, welded, bent, and rolled into a wide variety of shapes. It can also be drilled, tapped, silk-screened, and painted. Hardware can be inserted into the pieces and the finished product can then be riveted or welded together. One of the most common uses for sheet metal is in architectural applications. This includes items like doors, frames, and roofs for buildings. It is also used in the creation of various appliances and consumer electronics.
Sheet metal can be shaped by a number of processes including bending, rolling, and folding. These processes involve using specialized machines to apply controlled force to reshape the metal sheets. Rolling involves passing a piece of metal through a series of rollers to thin it and give it a particular shape. Other techniques include shearing which cuts straight lines in the metal and laser cutting which can be used to create intricate patterns on the metal surface.
Industrial Applications
Sheet metal fabrication is used by industrial clients to create products like point-of-sale stands, portable display cubes, and more. These types of projects require a mixture of aesthetics and durability and often use materials like stainless steel. Steel is an ideal material for fabricated metal since it offers strength and durability, while also being lightweight and easily shaped.
Other industrial applications include cladding for buildings and fireproof roofing. For these types of jobs, sheet metal fabricators must be able to make complex curves, which requires a lot of skill and experience. Forming is another type of fabrication process that reshapes metal into specific contours. It can be done using machinery like hydraulic brakes, rolling machines, and oxy-acetylene torches.
Customization and Precision
Metal fabrication allows for a high degree of customization in both product design and production. Sheet metal fabrication can create small or large products, from standard parts to complex structures. This process can also be used to repair or modify existing metalwork. For example, an engineer can create custom replacements for damaged or rusty sheet metal components.
Various Ways to Shape Sheet Metal
There are various ways to shape and alter sheet metal, including cutting, bending, and stretching.
- Punching and shearing are common cuts, while machining and arc welding are important deformation processes.
- Laser-beam cutting uses a concentrated beam of light to cut through and engrave metal, offering precise cuts in a range of thicknesses.
- Metal fabrication is ideal for a wide variety of applications, from automotive manufacturing and construction to aerospace and robotics.
- Every day, you likely use products like mailboxes, roof gutters, and cell phone casings that are created through metal fabrication.
Additionally, emergency vehicles rely on sheet metal fabrication to construct parts like glove-box enclosures, side steps, and door-handle mounts. Metal fabrications are strong and durable, able to withstand the elements and heavy use.
Safety Measures
Sheet metal fabrication involves a variety of processes, including welding, cutting, bending, and shearing, and it is therefore essential to take comprehensive safety measures. These measures can include wearing appropriate PPE, following safe material handling procedures, and maintaining an organized work environment. Welding is one of the most dangerous areas for a Sheet Metal Fabricator to work, as the potential for injuries is high. Metal can get extremely hot when heated and cold when cooled, and workers must ensure that they use proper welding techniques in order to avoid burns or other injuries.
Other dangers posed by the work can include cuts and punctures from shears and sharp corners, as well as strains and sprains from heavy lifting. In addition, the fabrication process can produce dust and other airborne particles that could be inhaled and cause harm to the lungs. Keeping the workspace clean and orderly is also crucial as it reduces tripping hazards and makes it easier to keep track of materials. You need to work like Architects of Modern Sheet Metal Fabricators.
Summary
Sheet metal fabrication involves using complex machinery to form, bend, and cut metal into any preferred shape. This method of production can work with a variety of metals including stainless steel, aluminum, copper, brass, and zinc. It can also be used to make products like automotive parts, construction hardware, and consumer goods. There are three main types of sheet metal fabrication: forming, cutting, and joining. Forming includes processes such as stamping, drawing, hemming, and stretching. While forming reshapes the flat metal, cutting subtracts material from it.