What is Sheet Metal Fabrication-----This Blog can Tell You All.

What is Sheet Metal Fabrication?

A manufacturing process transforming metal sheets (≤16mm thick, including aluminum alloys) into components using:

• Shearing 

• Punching 

• Press brake bending 

• Welding 

• Riveting 

• Stamping/forming 

Key characteristic of sheet metal parts:
Uniform wall thickness throughout a single component.

Common Sheet Metal Fabrication Techniques

Sheet metal fabrication involves multiple processes including cutting, punching, bending, welding, etc.

Sheet Metal Cutting

Primarily used to separate metal sheets into parts of specified shapes/sizes per design requirements. Methods include:

• Mechanical Cutting

• Shearing

• Punching/Blanking

• Laser Cutting

• Plasma Cutting

• Waterjet Cutting

• Manual Cutting

  • Oxy-fuel Cutting

  • Hand Saw Cutting

Laser Cutting:
A high-precision, efficient method using a high-energy-density laser beam to melt/vaporize material.
Advantages:

• High precision: ±0.1mm tolerance

• High speed: Ideal for thin sheets

• Complex contours: Cuts intricate curves/patterns

• Minimal HAZ (Heat-Affected Zone)

• No tooling required: Cost-effective for prototypes/low-volume

CNC Turret Punch Press:

• Processes various sheet metal parts with automatic complex hole punching/shallow forming

• Nibbling: Creates large round/square/obround holes via step punching

• Special techniques: Blind holes, shallow draws, countersinks, flanged holes, embossing, ribs

Sheet Metal Bending

A common forming process applying force beyond material yield strength using dies/tools to create plastic deformation.

CNC Press Brake Operation:

• Precision bending with ±0.1° angular tolerance

Sheet Metal Welding

Joins metal sheets by melting base material/filler under heat/pressure. Common processes:

• CO₂ Welding (GMAW)

• TIG/MIG Welding (GTAW/GMAW)

• Laser Welding
  Selection depends on material/thickness requirements.

Sheet Metal Fabrication Workflow

1. Design: Customer provides drawings/3D models → Engineering creates flat patterns & assembly drawings

2. Material Selection: Choose appropriate metal (see materials section below)

3. Pre-treatment: Degreasing/cleaning/surface preparation

4. Laser Cutting: Precise contour cutting (±0.1mm)

5. (Optional) CNC Punching: Hole piercing/notching/embossing

6. Bending: Form 3D shapes via press brake

7. Welding: Join components as needed

8. (Optional) Surface Treatment: Powder coating/plating/polishing

9. Assembly: Final product integration

Sheet Metal Materials Selection

Surface Treatments

Pre-treatment: Remove oil/rust/welding slag
Common Finishes:

• Powder Coating

• Electroplating (Zn/Ni/Cr)

• Hot-Dip Galvanizing

• Anodizing (Aluminum)

• Brushing

• Screen Printing

Material-Specific Treatments:

• Aluminum: Anodizing/powder coating

• SPCC: Powder coating/painting

• SGCC: Electroplating

• SECC: "N" material (bare), "P" material (painted)

Key Terminology Used:

• HAZ = Heat-Affected Zone

• Nibbling

• Turret Punch Press 

• Yield Strength

• Plastic Deformation

• EMI = Electromagnetic Interference

• CRS = Cold Rolled Steel

• EGS = ElectroGalvanized Steel

• GI = Galvanized Iron