In manufacturing and forming parts, techniques may vary depending on the desired end product, budgetary constraints and industry standards. There are a wide variety of methods and approaches to consider. Manufacturers can use metal fabrication to create innovative products and complex shapes and then test, finalize and/or distribute based on their goals.
This article will examine custom part manufacturing and forming techniques that manufacturers should consider and discuss common sheet metal fabrication methods to help you make an informed decision. By making informed metal fabrication choices, you will be better able to meet your customers' needs without sacrificing quality or extending lead times.
Custom part manufacturing and forming techniques to consider
Advanced part manufacturing and forming uses multiple methodologies with varying lead times, manufacturing requirements, and results. Here are a few to contemplate.
Metal cutting
The manufacturing and forming of parts regularly begins with the cutting of sheet metal. Firstly, the thickness and material are determined depending on the design specifications. After the design phase, the metal is typically cut using one or more techniques, some of which may be performed by computer numerical control (CNC) machining experts:
Cut
Sheet metal shearing is a process in which a large cutting tool, known as scissors, is used to cut straight lines in flat metal. It offers clean, straight cuts and is often used to trim larger sheets to a more manageable size before going through other manufacturing processes.
Hydrojetting
Waterjet, also known as waterjet cutting, is a method in which high-pressure water, usually mixed with an abrasive material, is used to cut sheet metal. This non-thermal process is precise, versatile and ideal for cutting heat-sensitive materials, both delicate and hard, without distorting the inherent properties of the material.
Laser cut
In laser cutting , the operator uses a high-powered laser beam to cut precise shapes from sheet metal. It offers excellent precision, high speed and the ability to cut complex shapes, requiring expert operation and monitoring to achieve optimal results.
Fire cuts
Burning sheet metal, usually through methods such as plasma cutting, uses a concentrated flame or jet of plasma to cut the material. This method can handle thicker materials efficiently and is useful for larger, less precise cuts. Typically, fabrication shops tend to avoid burning whenever possible, as this can be tedious with labor and time with large quantity orders.
Sawing
Sawing sheet metal is a traditional method in which various types of saws such as circular saws or band saws are used to cut material. This method is generally used for larger, straight cuts and can be effective for both thin and thick metals. Although this method is generally not ideal for repeatability.
metal bending
Cutting metal doesn't always make it ready for mass production. Operators may also have to perform other processes, such as bending to form complex shapes. Once the metal is cut, crews can use any of the following metal bending techniques to continue the process:
Form folding
Shape bending is a more general term for bending metal into desired shapes. This process is used to create simple bends and curves in sheet metal. It involves applying pressure to specific points along the sheet metal, often using a die and press, to produce the desired shape. Shape bending allows the creation of complex, non-linear bends in sheet metal – it is often used for parts that require curves or angles other than simply straight bends.
Metallic Braking
Metal braking, or press braking, involves placing sheet metal on a flat surface over a shaped die and applying pressure using a punch to create a bend. The press brake applies uniform pressure across the entire length of the metal, ensuring precise bends. This technique is typically used to create straight line bends, like flanges on a metal box.
Metal welding
Manufacturing relies on metal welding —a process in which two or more pieces of metal are joined by applying heat, often with the addition of a filler material to form a strong joint. There are also several options in this category, including:
GMAW/MIG welding
Gas metal arc welding (GMAW), commonly called metal inert gas (MIG) welding, is a versatile process that uses a continuously fed wire electrode and an inert gas, such as argon or helium, to protect the weld from atmospheric contaminants. This technique is preferred for its speed and adaptability in joining metals of different types and thicknesses.
TIG welding
Tungsten inert gas (TIG) welding uses a non-consumable tungsten electrode and an inert gas shield. Manufacturers use TIG welding to cut complex shapes out of thick sheet metal. Be aware, however, that the robust cutting tools used in TIG welding can increase the price of your project.
Flux Core Welding
Flux-Core Arc Welding (FCAW) is a variant of MIG welding that uses a special cored wire filled with flux, eliminating the need for external shielding gas. The flux provides the necessary protection against environmental contamination, making FCAW a good choice for outdoor applications and for welding thicker materials.
SMAW welding
Shielded metal arc welding (SMAW), commonly known as stick welding, employs a flux-coated electrode that provides the shielding necessary to protect the weld pool. This type of welding stands out for its simplicity and portability, making it a popular choice for construction, maintenance, and repair work.
Laser beam welding
Laser beam welding (LBW) is a precision process that uses a concentrated beam of light to form a strong, precise weld at high speeds. Often used for its ability to work on small, delicate parts, LBW is also ideal for joining dissimilar or difficult-to-weld materials due to its high density and energy control.
Metal Shrinking and Stretching
Metal shrinking and stretching are primarily used to create complex shapes, such as curves and contours, in sheet metal parts, such as those found in automobile bodies, aircraft structures, and custom metal art. Here are some customizable metal shrinking and stretching options:
Thermal shrinkage
Thermal contraction involves applying concentrated heat to a specific area of sheet metal, causing it to contract and effectively “shrink” in size. Experts use this technique in metal forming to remove dents and deformities or to shape curved elements in sheet metal components.
metal bending
Metal bending involves creating small folds or “folds” in sheet metal to decrease its surface area. This technique is used to produce complex shapes or to correct distortions, especially in custom automotive or aircraft panels where specific curves or contours are required.
Other custom parts manufacturing techniques
The techniques below can also be used to create unique metallic shapes:
- Metal Stamping —Sheet metal is pressed or punched to create custom shapes, patterns, designs and cutouts.
- Pressure casting —Molten metal under high pressure is forced into a mold cavity to create complex metal shapes.
- Metal Spinning— Spun metal parts are spun at high speed and formed on a lathe into an axially symmetrical part using a forming tool.
