Hey there, fellow CNC machinists, ever stopped to think about the sheer versatility of sheet metal fabrication and how it influences the world around us? From the sleek body of your card to the life-saving medical equipment in hospitals, the uses of sheet metal fabrication plays a crucial role in shaping the objects we interact with every day.

In this blog, we’ll dive into the world of sheet metal fabrication and explore its applications across various industries. Let’s begin.

Table of Contents: 

1. 1. Automotive Industry
   2. Aerospace and Aviation
   3. Architecture and Construction
   4. Electronics and Technology
   5. Medical and Healthcare
   6. Transportation and Logistics
   7. Defense and Military
   8. Mining Industry
   9. How does MDA help with Sheet Metal Fabrication?

This is the most prominent and popular use of sheet metal fabrication. With such a massive industry, there is a need for intricate parts. And the reason is simple: sheet metal is incredibly versatile and durable.

Here are some industrial uses of sheet metal fabrication in the automotive industry:

• Body Panels

Manufacturers widely use it to produce body panels for cars, including doors, hoods, fenders, roofs, and trunk lids. Through processes like stamping, deep drawing, and hydroforming, they transform flat metal sheets into precisely shaped panels, meeting design specifications with uniformity and consistency. This approach ensures the desired aesthetic appeal of vehicles.

• Chassis Components

It is essential in making chassis components, the structural backbone of vehicles, comprising frame rails, crossmembers, floor pans, and suspension mounting points. These parts, typically crafted from high-strength steel sheets, undergo laser cutting, bending, and welding for fabrication. Sheet metal processes ensure the structural integrity and durability of chassis components, offering the strength and rigidity needed to support vehicle weight and handle dynamic loads during operation.

• Interior Features

Manufacturers use it to craft interior features for automobiles, such as dashboard structures, door panels, seat frames, and console enclosures. These components offer structural support and serve as mounting points for interior accessories such as airbags and infotainment systems. Sheet metal techniques ensure precise shaping and assembly of these parts, enhancing the comfort, functionality, and aesthetics of vehicle interiors.

In the aerospace and aviation industry, sheet metal fabrication serves several industrial purposes, contributing to the production of various components and structures essential for aircraft manufacturing. Here are some key industrial uses of sheet metal fabrication in this sector:

• Aircraft Fuselage

It is crucial in aircraft fuselage construction, forming the aircraft’s main body. Using processes like stretch forming and hydroforming, manufacturers shape flat metal sheets into large fuselage sections. They then join these sections via riveting or welding to create the cylindrical fuselage shape. Sheet metal fabrication ensures precise shaping, enhancing structural integrity and aerodynamic efficiency.

• Wing Structures

Manufacturers use it to make wing structures like skins, ribs, and spars. They shape thin metal sheets using stamping, bending, and machining techniques. Precision fabrication ensures components meet strict standards, enhancing aerodynamic performance and structural strength.

• Engine Components

It is essential in making engine components like nacelles, cowls, and exhaust ducts from heat-resistant alloys. Using processes such as hot forming and superplastic forming, durable components are produced. This ensures engine efficiency and performance, crucial for aircraft propulsion systems.

In the architecture and aviation industries, sheet metal fabrication serves several industrial purposes, contributing to the production of various components and structures essential for building construction and aircraft manufacturing. Here are some key industrial uses of precision sheet metal fabrication in these sectors:

• Architectural Cladding

It is crucial in architectural cladding, covering building exteriors with metal panels for both aesthetic and functional reasons. These panels, made from materials like aluminum, stainless steel, or copper, undergo processes such as roll forming, bending, and welding. This ensures precise shaping, providing weather protection, thermal insulation, and enhancing the architectural appeal of buildings.

• Roofing Systems

It is used in making roofing systems for buildings, like standing seam roofs, corrugated roofs, and metal shingles. These materials usually galvanized steel or aluminum, undergo processes such as roll forming and stamping to create different profiles and shapes. Sheet metal fabrication ensures durability, weather resistance, and aesthetic appeal, enhancing building longevity and performance.

• Structural Components

It is essential for producing structural components in both architecture and aviation. In buildings, manufacturers use sheet metal to create beams, columns, and trusses, providing support and stability. In aircraft, they use sheet metal for fuselages, wings, and empennage, enhancing strength and integrity.

Sheet metal fabrication plays a crucial role in the Electronics and Technology Industry, where precision and efficiency are paramount. Here are some key industrial uses:

• Enclosures and Cabinets

Sheet metal is commonly used to manufacture enclosures and cabinets for electronic devices such as computers, servers, routers, switches, and control panels. These enclosures protect from environmental factors like dust, moisture, and electromagnetic interference (EMI).

• Chassis and Frames

It is used to create chassis and frames for electronic equipment. These structures provide support and housing for internal components such as circuit boards, power supplies, and cooling systems. They also contribute to the structural integrity and durability of the equipment.

• Custom Prototyping and Production Runs

It allows for the creation of custom parts and prototypes tailored to the specific needs of electronics manufacturers. Whether it’s a unique enclosure design or specialized mounting brackets, sheet metal fabrication enables rapid prototyping and cost-effective production runs.

Sheet metal fabrication plays a crucial role in the medical and healthcare industry, providing various components and equipment necessary for patient care, medical devices, and facility infrastructure. Here are some industrial uses of sheet metal fabrication in this sector:

• Medical Equipment Enclosures

Manufacturers commonly use sheet metal to create enclosures for medical equipment such as diagnostic machines, MRI and CT scanners, and laboratory instruments. These enclosures protect sensitive electronic components and ensure safety for patients and operators.

• Ventilation Systems

Proper ventilation is critical in healthcare facilities to maintain air quality and prevent the spread of airborne contaminants. It is used to create ventilation ducts, hoods, and exhaust systems that ensure efficient airflow and compliance with health and safety regulations.

• Medical Carts and Cabinets

Sheet metal fabrication produces durable carts and cabinets crucial for storing and transporting medical supplies in hospitals and healthcare facilities. They’re sturdy, lightweight, and easy to maneuver, enduring daily clinical demands.

Sheet metal fabrication plays a role in the transportation and logistics industry, providing various components and structures necessary for vehicles, infrastructure, and equipment. Here are some key industrial uses:

• Vehicle Manufacturing

Manufacturers extensively use it in the production of vehicles, including cars, trucks, buses, trains, and airplanes. They employ it to create body panels, chassis components, frames, and structural supports, which contribute to the overall strength, durability, and safety of the vehicle.

• Cargo Containers

Manufacturers commonly use sheet metal to make shipping containers for transporting goods via sea, rail, or road. They weld or rivet fabricated sheet metal panels together to form these containers, providing robust and weather-resistant enclosures for various types of cargo.

• Vehicle Interiors and Accessories

Sheet metal is also used for fabricating interior components and accessories in vehicles and transportation equipment. This may include dashboards, door panels, seating structures, instrument panels, and storage compartments.

Sheet metal fabrication plays a crucial role in various aspects of the Defense and Military industry due to its versatility, durability, and strength. Here are some common industrial uses of sheet metal fabrication in this sector:

• Armor and Vehicle Components

Sheet metal is widely used in the fabrication of armored vehicles, tanks, and personnel carriers. It protects against ballistic threats, blasts, and environmental hazards. Armored plates made from sheet metal are often used to reinforce critical areas of military vehicles.

• Weapon Systems

Many weapon systems, including firearms, missiles, and artillery, rely on components produced through sheet metal fabrication. Manufacturers often make gun casings, missile bodies, and ammunition containers from sheet metal due to its ability to withstand high pressures and impact forces.

• Communications and Electronics

Sheet metal is used in the fabrication of enclosures and chassis for electronic equipment, communication systems, and radar installations. These components protect from electromagnetic interference (EMI), environmental hazards, and physical damage.

Sheet metal fabrication plays a crucial role in the mining industry, providing solutions for various needs including equipment manufacturing, infrastructure development, and maintenance. Here are some industrial uses of sheet metal fabrication in the mining industry:

• Equipment Manufacturing

It is used to manufacture a wide range of mining equipment such as conveyor systems, chutes, hoppers, and tanks. These components are essential for material handling, transportation, and processing within mining operations.

• Protective Enclosures and Barriers

It is utilized to create protective enclosures and barriers for sensitive equipment and hazardous areas within mining sites. These enclosures help safeguard equipment from environmental elements and prevent unauthorized access to restricted areas.

• Tooling and Fixtures

It is used to produce tooling and fixtures required for various mining processes such as drilling, cutting, and welding. These specialized tools and fixtures enhance efficiency and accuracy in mining operations, contributing to overall productivity and quality.

Looking for a reliable sheet metal fabrication partner? MDA is your answer! We excel in providing top-tier services across various industries like automotive, aerospace, and medical. Our seasoned professionals commit to delivering excellence, regardless of the project’s complexity. With cutting-edge technology and equipment, we ensure precision and accuracy in every project.

Choose from a range of fabrication services, all seamlessly handled by our state-of-the-art machinery. Whether it’s a prototype or high-volume production, trust our experts to deliver affordable solutions without compromising quality. Count on us for on-time delivery and budget-friendly services.

Table of Contents: 

1. Introduction
2. The Process of Sheet Metal Fabrication
3. Materials & Applications of Sheet Metal Fabrication
4. Surface Finish of Sheet Metal Fabrication
5. Advantages of Sheet Metal Fabrication
6. Conclusion

Sheet metal fabrication is all about crafting parts from thin sheets of metal. Whether it’s shaping straightforward designs or creating intricate components, this sheet metal fabrication guide covers it all. Therefore, in this article, we’ll delve into our sheet metal fabrication guide and offer insights into designing and producing products through this method.

First, cut metal into flat sheets. Then, use various processes, such as stamping, bending, or welding, to form these metal sheets into the desired shape. Finally, add a coating or surface treatment to finish the part.

Step 1: Cutting sheet metal materials

There are 5 methods for cutting materials for sheet metal fabrication processes:

• Shearing: This process involves using straight-cutting blades to make straight-line cuts in sheet metal. It suits cutting large pieces quickly and is often used for simple shapes and straight edges.
• Laser cutting: Laser cutting uses a high-powered laser beam to cut through sheet metal. It offers precision and versatility, allowing for intricate designs and complex shapes to be cut with ease.
• Water jet cutting: Water jet cutting involves using a high-pressure stream of water mixed with an abrasive substance to cut through sheet metal. It’s suitable for cutting materials that may be sensitive to high temperatures and offers precise cutting with minimal material distortion.
• Plasma cutting: Plasma cutting uses a plasma torch to cut through electrically conductive materials, including sheet metal. It’s a fast and efficient method, suitable for cutting thick materials and producing clean edges.
• Mechanical cutting: Mechanical cutting methods, such as sawing or milling, involve using mechanical tools to cut through sheet metal. While not as common in sheet metal fabrication, these methods can be useful for specific applications or materials.

Step 2: Punching & Broaching

Punching is a sheet metal fabrication method that uses a punch to create holes or shapes in the metal. It can be done with various tools, like an automatic punch, a hand punch, or a CNC machine.

There are three types of punching:

• Single punching: This method involves using a single punch and die set to create a hole or feature in the sheet metal. The punch is forced through the material, cutting out the desired shape. Single punching is suitable for simple hole patterns or individual features.
• Nibbling:  Also known as notching, involves using multiple overlapping punches to gradually remove material from the sheet metal. Manufacturers often use it to create irregular shapes and internal cutouts.
• Progressive punching: Progressive punching involves a series of sequential punches and dies mounted on a single tool. Progressive punching is efficient for high-volume production of parts with multiple features.

Step 3: Pressing Rivet

When riveting nuts, screws, or other fasteners to sheet metal components using hydraulic riveting machines or punches, therefore, it’s crucial to ensure proper orientation of the riveting nuts.

Step 4: Sheet Metal Bending

Sheet metal bending involves transforming 2D flat pieces into 3D parts by folding. This process requires a folding bed and bending mold to be completed, following specific bending orders and steps. It entails bending sheet metal into the desired shape and angle as specified in the drawing.

Step 5: Welding

Sheet metal welding involves joining multiple parts together or welding the edges of a single part to enhance its strength. Common welding techniques for sheet metal include TIG welding, MIG/MAG welding, gas-shielded welding, laser welding, and more.

Step 6: Polishing

Following welding procedures, the surface should be polished using emery cloth to eliminate any rough edges, welding slag, spots, burrs, etc. The welded area must be smooth and seamless, with no visible imperfections.

Step 7: Surface Finish

Upon completion of processing sheet metal parts, surface treatment is necessary to safeguard the workpiece, improve its appearance, and prolong its operational lifespan.

Sheet metal fabrication involves working with thin metal sheets to create various components. Here’s an overview of common materials used in sheet metal fabrication and their applications:

• Steel: Steel ranks among the most widely used materials in sheet metal fabrication due to its strength, durability, and versatility. It comes in various grades and finishes, including mild steel, stainless steel, and galvanized steel. Fabricators often choose mild steel for its affordability and ease of fabrication, while they select stainless steel for its corrosion resistance, making it suitable for harsh environments like marine or food processing industries.
• Aluminum: Engineers value aluminum for its lightweight properties, corrosion resistance, and conductivity. They commonly use it in industries such as aerospace, automotive, and electronics. Aluminum alloys provide a wide range of mechanical properties and are easy to form and weld, making them suitable for intricate designs.
• Copper: Copper’s excellent conductivity, corrosion resistance, and aesthetic appeal make it a prized material. Manufacturers commonly use it in electrical and electronic applications where high conductivity is essential. Additionally, copper sheet metal serves well in architectural applications.
• Brass and Bronze: Brass and bronze are alloys of copper with varying amounts of zinc or tin. They offer unique combination of properties, including corrosion resistance, machinability, and aesthetic appeal. Brass is often used in decorative applications, hardware, and musical instruments, while bronze is favoured for its strength and wear resistance in applications such as bearings and bushings.
• Titanium: Titanium’s high strength-to-weight ratio, corrosion resistance, and biocompatibility make it highly valued. Industries commonly use it in aerospace, medical, and marine applications where lightweight and durable materials are required.

There are plenty of types of surface finishes that can be applied to sheet metal fabrication. The most common type of finish is anodizing and other finishes include sand blasting, powder coating, painting and plating. Let’s check them out:

• Anodizing: Anodizing is a method that forms a protective coating on metal surfaces. While commonly applied to aluminum, it can also be utilized on other metals like stainless steel and titanium.
• Sand blasting: Sandblasting involves using high-pressure air to propel sand onto metal surfaces. While this process results in a metallic-coloured surface on the workpiece, its rough texture refracts light, resulting in a lack of metallic lustre and a darker appearance.
• Powder coating: This finish is applied to metal using a powder rather than paint. It offers enhanced durability compared to paint, making it less susceptible to chipping or fading.
• Electroplating: This process involves applying a thin layer of another metal onto the surface of the metal using an electric current. Such a finish is commonly employed to enhance the appearance of the workpiece or to provide protection against corrosion.

Here are some advantages you can find in our sheet metal fabrication guide:

• Versatility: Sheet metal fabrication offers versatility in design, allowing for the creation of complex shapes and structures to meet specific requirements.
• Strength: Sheet metal is inherently strong and durable, providing robustness and stability to fabricated components and products.
• Efficiency: Sheet metal fabrication processes, such as cutting, bending, and welding, can be automated or performed rapidly, resulting in efficient production and shorter lead times.
• Customization: Sheet metal fabrication allows for customization of designs to suit unique project needs, whether it’s prototyping, one-off production or mass manufacturing.
• Material variety: Sheet metal comes in a variety of materials, including steel, aluminum, copper, and alloys, providing flexibility in material selection based on factors such as strength, corrosion resistance, and conductivity.
• Precision: With advancements in technology and machinery, sheet metal fabrication offers high precision and accuracy in producing components with tight tolerances.

Sheet metal fabrication is a great choice for high-strength, durable parts that are also lightweight and cost-effective. The process is relatively simple and can be completed quickly. Widely used in many different industries, sheet metal fabrication is a versatile option for your next project.

I hope you learned via this sheet metal fabrication guide and how you can use it to create parts for your project and find the right sheet metal fabricators.