Sheet Metal Prototyping Fabricatio

Made to order from 1 to 10,000 pieces on demand
One-on-one support service Response within 12 hours
In-house machine shop, 24/7 operations, Quick turnaround
Wide range of machining technicals. Tight tolerances, Finer surface finishes.
ISO 9001:2015 certified 100% part inspection

Our Sheet Metal Fabrication Services

IDEAL'S custom sheet metal prototyping services offer a fast and cost-effective solution for your projects. Services including bending, punching, cutting standard gauge metal for both prototypes and low volume production runs. Sheet metal fabrication produces durable, end-use metal parts with a wide selection of materials and finishes that meet your specifications, for a variety of industries like: Automotive, Medical device, Aerospace, electronics, energy and robotics.

Advantages of Sheet Metal Fabrication

01
Wide Range of Material and Surface Finish Options

Suitable for various metals, including steel, aluminum, stainless steel, copper, and brass. Offers multiple surface finishing options, including powder coating, anodizing, painting, and polishing.
02
Speed and Efficiency

Quick turnaround times for producing parts, particularly with automated processes. Faster design-to-production cycles due to efficient manufacturing processes and advanced machinery.
03
Scalability

Effective for both small and large-scale production, from prototypes to mass production.
04
Design Flexibility

Capable of producing intricate and complex designs, including bends, folds, and deep draws, and allows for easy modifications and adjustments during the design phase or after production.

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How Sheet Metal Fabrication Works?

Sheet metal fabrication involves a series of steps including material selection, design, cutting, forming, joining, machining, and finishing to transform flat metal sheets into complex and functional components. IDEAL managing each step and adhering to safety and quality standards, manufacturers can produce precise and durable parts for a wide range of applications. Here's a detailed overview of how sheet metal fabrication works:

Material Selection, Design & Planning

Metal Type: Choose the type of metal sheet based on the application and requirements. Common metals include steel, aluminum, stainless steel, copper, and brass.

Thickness and Gauge: Determine the thickness or gauge of the sheet metal, which affects the strength and flexibility of the finished product.

Blueprints and CAD Models: Develop detailed designs using computer-aided design (CAD) software. This ensures precision and accuracy in the fabrication process.

Cutting Patterns: Create cutting patterns or layouts to maximize material efficiency and minimize waste.

Cutting & Forming

Shearing: Straight-line cuts are made using a shear machine. This method is efficient for cutting large sheets into smaller pieces or basic shapes.

Laser Cutting: Uses a high-powered laser beam to make precise and complex cuts. Ideal for intricate designs and high precision.

Waterjet Cutting: Employs a high-pressure jet of water mixed with abrasives to cut through thick or sensitive materials without heat.

Plasma Cutting: Uses a plasma torch to cut through electrically conductive metals. Suitable for thicker sheets and less precision compared to laser cutting.

Bending: Changes the shape of the metal by bending it along a straight line using a press brake. This process creates angles or curves in the sheet.

Stamping: Uses dies and punches to shape or emboss the metal. This process is commonly used for high-volume production of parts with repeating features.

Deep Drawing: Involves drawing the metal into a die cavity to create deep or hollow shapes. Useful for making complex shapes with a single piece of metal.

Joining & Secondary Machining

Welding: Fuses metal pieces together by melting and re-solidifying them. Common welding methods include MIG (Metal Inert Gas), TIG (Tungsten Inert Gas), and spot welding.

Riveting: Joins metal parts by inserting and fastening rivets. Suitable for situations where welding is not practical.

Screws and Bolts: Mechanical fasteners used for assembling metal components, allowing for disassembly and adjustment.

Drilling: Creates holes in the sheet metal using drills or CNC machines. Essential for adding mounting points or other features.

Milling: Removes material from the sheet metal to shape or finish parts using a rotating cutter.

Surface Finishing

Deburring: Removes sharp edges or burrs left from cutting or machining processes to ensure safety and a smooth finish.

Grinding: Smoothens and refines surfaces or edges using abrasive wheels or belts.

Sanding and Polishing: Further smoothens and refines the surface to achieve a desired texture or shine.

Coating: Applies protective or decorative coatings such as powder coating, painting, or anodizing to enhance appearance and performance.

Quality Control, Assembly & Integration

Inspection: Regularly inspect the fabricated parts to ensure they meet design specifications and quality standards. This includes visual inspection and dimensional checks.

Testing: Perform tests to verify the performance and durability of the parts, such as strength tests or corrosion resistance tests.

Assembly: Combine individual fabricated parts into the final product using methods like welding, riveting, or mechanical fastening.

Integration: Incorporate the fabricated components into larger systems or products as required.

Sheet Metal Fabrication Service We Are Offering

Laser Cutting

Entailing the focusing of a beam of high density energy on the surface of the workpiece, laser cutting involves the controlled evaporation of a portion of the workpiece. Laser cutting is able to deliver a high quality cut and narrow kerf, and can be used to cut aluminum (using a higher power laser), plain steel, stainless steel and spring steel.

Types of Lasers and Their Cutting Capabilities

CO2 Lasers: CO2 lasers are versatile and used for cutting various materials, including metals, plastics, and wood. Typical Thickness Up to 25 mm for mild steel; up to 12 mm for stainless steel; and up to 6 mm for aluminum, up to 50 mm for acrylic or wood.
Fiber Lasers: Fiber lasers are particularly effective for cutting metals with high precision and speed. Typical Thickness Up to 30 mm for mild steel; up to 20 mm for stainless steel; and up to 12 mm for aluminum.
Nd: Often used for high-precision and small-scale cutting, such as in medical and industrial applications. Typical Thickness Up to 6 mm for metals.

Typical Tolerances

General Tolerances: Typically range from ±0.1 mm to ±0.5 mm. Thinner materials allow for tighter tolerances due to less heat distortion and better beam focus.
High Precision Tolerances: As tight as ±0.05 mm or better. Achieving these tight tolerances often requires advanced laser cutting systems and careful control of process parameters.

More Resources:
Laser Cutting VS. Plasma Cutting VS. Water Jet Cutting
Punching

Punching is a widely used manufacturing process that involves creating holes or shapes in sheet metal or other materials using a punch and die.

Types of Punching and Their Capabilities

Mechanical Punching: Use a mechanical system, often a flywheel, to transfer energy to the punch. Suitable for high-volume production. Ideal for high-speed, high-volume operations with standard shapes.
Hydraulic Punching: Utilize hydraulic cylinders to apply force. They offer greater control and are ideal for thicker materials or complex shapes. Cater to varying material thicknesses and complexities.
Pneumatic Punching: Use compressed air to drive the punch. Often used for lighter, less complex operations. Cater to varying material thicknesses and complexities.
Laser Punching: Some machines integrate punching with laser cutting for enhanced versatility and precision.

General Tolerances

Standard Tolerances: typical range from ±0.1 mm to ±0.5 mm. This range covers most common applications where moderate precision is required. Thinner materials generally allow for tighter tolerances due to reduced heat distortion and better punch-to-die alignment.
High Precision Tolerances: ±0.05 mm or even tighter can be achieved with advanced punching equipment and well-maintained tooling.
Bending

Bending is a manufacturing process used to shape metal or other materials into desired angles and curves by applying force. It's a fundamental technique in metalworking and fabrication, employed to create various components and products across industries.

Types of Bending

Air Bending: The bend angle is controlled by the depth of punch penetration and the material's springback. Suitable for a range of bend angles and radii.
Bottoming (or Coining): The punch makes complete contact with the die, reducing the impact of material springback. Provides high precision and consistent bend angles, ideal for complex and tight-radius bends.
Wipe Bending: The punch moves across the material's surface to create the bend. Useful for creating large-radius bends or bends in very thin materials.
Rotary Bending: Utilizes a rotating tool to bend the material around a set radius. Suitable for creating smooth, continuous bends in tubes and profiles.
Roll Bending: Involves passing the material through a set of rollers to achieve a curved shape. The rollers apply gradual pressure to create bends. Ideal for large-radius bends and cylindrical shapes.
Press Brake Bending: Uses a U-shape or V-shaped die and a punch to create bends. Commonly used for standard bends and provides good precision for a range of angles.

General Tolerances

Standard Tolerances: Ranges from ±0.5 mm to ±1.0 mm. Thicker and harder materials require more force and can be more challenging to bend precisely, and the tendency of the material to return slightly to its original shape after bending affects final tolerance
High Precision Tolerances: for critical applications the tolerance ranges from ±0.2 mm to ±0.5 mm. Tighter tolerances are achievable with advanced equipment and careful process control.
Stamping

Stamping is a versatile and efficient manufacturing process used to create a wide range of parts and components. With various techniques such as blanking, punching, embossing, and forming, stamping can handle diverse material types and produce high-precision, high-volume parts.

Types of Stamping and Their Capabilities

Blanking: Removes a piece of material (blank) from a larger sheet.
Punching: Punching can create various shapes, such as holes, slots, or intricate patterns. Used for making holes in panels, brackets, and other components.
Embossing: Creates raised or recessed designs on the material's surface. The design is formed by pressing the material between a die and a counter-die. Used for decorative patterns, texturing, and branding on metal or other materials.
Forming: Shapes the material into three-dimensional forms by applying force to create bends, curves, or other shapes. Used for creating complex shapes like automotive panels, enclosures, and casings.
Drawing: Pulls the material into a die cavity to create deep or complex shapes. This technique stretches the material to form hollow parts.
Progressive Die Stamping & Compound Die Stamping: Progressive Die Stamping uses a series of dies in a single press to perform multiple operations on the material, which is Efficient for high-volume production of complex parts. Compound Die Stamping uses a single die to perform multiple operations simultaneously, which suit for creating parts with combined features, reducing the need for multiple operations.

Limitations of Stamping

Initial Tooling Costs: High initial investment in tooling and dies, which can be a barrier for low-volume production.
Material Limitations: Some materials may be challenging to stamp due to hardness or brittleness.
Design Constraints: Complex designs may require multiple stages or specialized tooling, increasing complexity and cost.

Welding and Assembling

Specializing in a number of welding processes, IDEAL's services range to include TIG Welding & MIG Welding.

Final assembly is then completed by using various processes ranging from welding and riveting, to threaded fasteners, adhesives and, in some cases, more bending processes.

TIG Welding

Also know as Gas Tungsten Arc Welding (GTAW), TIG welding is arc welding process involving the use of a non-consumable tungsten electrode in order to deliver a weld. With stainless steel, this type of welding can be done with our without the use of a filler wire.

MIG Welding

MIG welding entails the use of a filler metal in the form of wire. This wire is fed through the welding torch and delivers a higher welding speed than that seen in TIG Welding.

More Resources:

TIG Welding VS. MIG Welding

Why Choose Sheet Metal Fabrication From IDEAL?

Expert Project Management. IDEAL offers a number of fabrication processes, and meeting ISO 9001:2008 standards. Our skilled engineers and technicians provide timely communication and updates, ensuring project management from initial design for manufacturability (DFM) to shipment.

Wide range of capabilities. Including CNC bending, laser cutting, welding, press fitting, stamping and post finishing.

24/7 Operation and Flexibility. IDEAL often willing to work closely with clients to customized machining solutions according to specific design requirements. We always offer flexibility in terms of design modifications, prototyping, and iterative improvements.

Integrated Supply Chain and Global Logistics. With access to a comprehensive supply chain network facilitates sourcing of materals and components streamlining the production process. Our location in Guangdong Province( Shenzhen) enable effcient shipping of finished parts worldwide.

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Sheet Metal Materials

Sheet metal fabrication uses various materials, each offering distinct properties suited for different applications. Here are some commonly used sheet metal materials:s

Low Carbon Steel (Mild Steel)	Stainless Steel 441	Titanium Alloys
Medium Carbon Steel	Stainless Steel 410	Hot-Dip Galvanized Steel
High Carbon Steel	Stainless Steel 420	Electro-Galvanized Steel
Alloy Steel 4130	17-4 PH	High-speed Steel
Alloy Steel 4140	15-5 PH	Cold-work Steel
Nickel-Chromium Steel 4340	1000 series (pure aluminum)	Hot-work Steel
Stainless Steel 304	3000 series (aluminum-manganese)	Spring Steel
Stainless Steel 316	5000 series (aluminum-magnesium)	Nickel Alloy
Stainless Steel 321	6000 series (aluminum-silicon-magnesium)	Tool Steel D2
Stainless Steel 430	Bronze	Tool Steel A2
Stainless Steel 409	Brass

Our Maxime Size Range of Your Machine Ability

Maximum Dimensions 990.6mm x 1,193.8mm

Minimum Dimensions: Flat Part 6.5x 6.5 (mm); Formed Parts 13 x 13 (mm)

Overview of Sheet Metal Post-Processing

Surface finishing of sheet metal parts is essential to improve their appearance, functionality, and durability. It involves various techniques to alter the surface texture, remove imperfections, and apply protective coatings. Below are some common surface finishing processes IDEAL provided for sheet metal parts.

Polishing & Deburring & Grinding: Smoothing the surface and removing excess material or imperfections.

Sandblasting: Cleaning and texturing the surface by blasting it with abrasive materials under high pressure.

Chemical Etching: Using acid or other chemicals to remove material and create a textured or patterned surface.

Electroplating: Applying a thin layer of metal (such as chromium, nickel, or gold) to the surface using an electrochemical process. Improves corrosion resistance, enhances appearance, and can provide a hard surface.

Anodizing: An electrolytic process that converts the metal surface into an oxide layer to increase corrosion resistance and wear resistance,

Powder Coating: Applying a dry powder to the metal surface, which is then heated to form a durable, protective coating. Provides a uniform finish with excellent resistance to corrosion, impact, and weathering.

Painting: Applying liquid paint to the metal surface for protection and aesthetic purposes. Can be done via spray painting, roller coating, or dipping, and requires proper surface preparation for adhesion.

Passivation: Treating the metal surface, typically stainless steel, with acid to remove free iron and enhance corrosion resistance. Often used in the aerospace and medical industries to prevent rust and staining.

Hot-Dip Galvanizing: Coating the metal with a layer of zinc by immersing it in molten zinc. Provides excellent corrosion protection, commonly used for outdoor and structural applications.

Laser Marking: Using a laser to etch or engrave patterns, text, or logos onto the metal surface. Used for branding, identification, or decorative purposes.

Hardware Insertion: PEM hardware insertion and riveting are available secondary sheet metal processes. IDEAL providing insertion like Stand-offs, Clinch nuts, Studs/pins adn Panel fasteners.

Tapping and Countersinking: Tapping and countersinking of holes on a sheet metal design can help integrate hardware. Metric tapped holes available between M2 and M12.

Welding & Assembly: Gas metal arc welding (MIG) and gas tungsten arc welding (TIG) are possible on sheet metal parts at IDEAL.

Sheet Metal Fabrication Tolerances

IDEAL produce high quality fabrications ranging from wall dispensers to radar housings; from protective covers to generator cabinets; from air conditioning housings to brackets. To maintain our high standard of quality we use the latest technologies including CNC Laser Cutting, CNC Punch machines, CNC Bending machines, Robot Welding, Automated and Manual Powder Coating lines, etc.

Experienced engineers and purchasing officers will know, however, that the tolerances specified in drawings have a direct correlation to the manufacturing price of the part or product. Unnecessary blanket tight tolerances on a drawing may well double or treble the manufacturing cost!

This is why we work to two or three different levels of tolerances so that purchasers can benefit from lower prices where looser tolerances permit. This does not mean a drop in quality - simply a broader tolerance where applicable and where specified by our customers. This is how the grades affect pricing:

Grade A - Tightest tolerances
- Higher scrap rate allowance
- Greater and more frequent QC inspections
- Better tooling and jigs
- More specialized QC equipment
Grade B - Standard tolerances
- Standard scrap rate
- Standard QA inspections
- Standard tooling
- Standard QC equipment
Grade C - Broader tolerances
- Low scrap rate allowances
- Random sample QC inspections
- Possible low cost tooling
- Limited QC equipment required

DOWNLOAD SHEET METAL TOLERANCE GUIDE

Sheet Metal FAQS

Q: How To Choose From Laser Cutting, Water Jet Cutting Or Plasma Cutting?

A:

Evaluate these factors based on your specific project requirements to select the most suitable cutting method.
Material Thickness: Laser cutting excels with thinner materials, while water jet and plasma cutting handle thicker materials better.
Precision: Laser cutting provides the highest precision and cleanest edges.
Heat Sensitivity: Water jet cutting avoids heat distortion, unlike plasma and laser cutting.
Cost: Plasma cutting is generally more cost-effective for thicker materials, while laser cutting can be more expensive but offers high precision.
Q: Does It Cost more To Use Multiple Sheet Metal Forming Processes?

A:

Using multiple processes like bending and stamping can increase costs due to additional tooling, setup time, and potential material handling. It can, depending on the complexity and requirements of each process. In general, most sheet metal parts demand a combination of forming processes, and this will not increase the price by a drastic amount.
Q: How Does The Choice Of Material Affect Costs?

A:

The choice of material significantly impacts costs in several ways:
Raw Material Costs: Different metals have varying base prices. For instance, stainless steel is generally more expensive than mild steel due to its alloying elements and processing requirements.
Processing and Fabrication: Some materials are harder to work with than others. For example, aluminum is often easier to cut and bend compared to harder metals like titanium, which may require specialized equipment and techniques, increasing fabrication costs.
Tooling and Equipment: Different materials may require different tooling or modifications to existing equipment. For instance, harder metals can cause more wear on tools, necessitating more frequent replacements or upgrades.

Finishing and Treatment: Certain materials might need additional finishing treatments (like anodizing for aluminum or passivation for stainless steel) to achieve desired properties or aesthetics, which can add to the cost.
Material Waste: Some materials may result in more waste during cutting or forming processes. For example, thicker materials might require more trimming, which increases material costs.
Transportation and Handling: Heavier or bulkier materials can incur higher shipping and handling costs, especially if they require special packaging or equipment to move.
Q: What Are The Common Techniques Used For Sheet Metal Machining?

A:

Common techniques include:
1. Cutting: Methods like shearing, laser cutting, and water jet cutting to shape the metal.
2. Bending: Using presses or brake machines to form angles and curves.
3. Stamping: Applying pressure to a die to create complex shapes and patterns.
4. Welding: Joining metal pieces using heat and/or pressure.
5. Punching: Creating holes or shapes by punching out material from the sheet.

Request Your Free Sheet Metal

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Your customer support partner will contact you directly to ensure you've received and understand all aspects of your quotation and to answer any questions you may have.

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Sheet Metal Fabrication Cases

Quickly and costly get your molded parts with the production-grade material and technology process by using the rapid tooling,for low volume rapid injection molding.

See What Our Custom Say

My experience working with Fay was great.Clear communication that put me at ease. Very easy to order these parts. Great quality and werecieved exactly what we were expecting - Followed the engineered drawings precisely. Theproduct arrived well packaged, and precisely to spec.

Thank you very much for your consideration and problem solving. lt says a lot about your companyand 1feel comfortable working with you moving forward.

Chris

R&D Manager
IDEAL was able to deliver an accurate and quick service for high quality CNC parts. We inspected the parts, everything was within tolerance in terms of dimensions, and the surface finish on the machined faces is really good. IDEAL has always given us exactly what we needed.

Dennis J.

Engineer
Partnering with IDEAL has transformed our production process. Their precision, reliability, and commitment toquality have been game-changers for us. We've seen a remarkable improvement in efficiency and productquality, allowing us to meet our customers' demands better than ever. IDEAL's team truly understands oulneeds and consistently delivers beyond our expectations.

Jennie Elp.

Senior Mechanical Designer