Sheet metal fabrication involves the process of transforming flat sheets of metal into finished products or components. Sheet metal fabrication is the vital for various industries because it produces items ranging from simple metal parts to complex metal structural components such as brackets, enclosures, panels, and metal cabinets. Moreover, these hardware accessories constitute many various equipment and precision instruments in daily life and production. The following are key processes and technologies involved in sheet metal fabrication.
Design
The sheet metal fabrication process begins with the design phase. Furthermore, engineers and designers use computer-aided design software like CAD to create detailed plans, specifying dimensions, tolerances, and material requirements for the sheet metal components.
Material Selection
Once the design is finalized, the appropriate sheet metal material is selected. Common materials include steel, aluminum, stainless steel, and copper, each chosen for its specific properties such as strength, corrosion resistance, and conductivity.
Cutting
Cutting is a crucial step in sheet metal fabrication. Various cutting methods may be employed, including:
Shearing: Straight-line cutting using shear forces.
Laser Cutting: Uses a laser to cut through the metal sheet with precision.
Waterjet Cutting: Involves a high-pressure stream of water mixed with abrasive particles to cut through metal.
Plasma Cutting: Uses a high-temperature, ionized gas to melt and cut through the metal.
Punching
Punching creates holes or shapes in the sheet metal. Turret punching and CNC punching are common methods that use a punch press with different tools.
Turret Punching: A punch press with multiple tools creates holes and shapes in the metal.
Numerical Control (CNC) Punching: Computer-controlled machines for punching precise patterns.
Bending
Bending is achieved using a press brake, which applies force to the sheet metal to bend it into the desired shape. Moreover, this step is crucial for creating angles and forming the predetermined shapes final product.
Forming
Forming processes, such as roll forming and deep drawing, shape the sheet metal into three-dimensional forms.
Roll Forming: Continuous bending of a metal sheet as it passes through sets of rolls.
Deep Drawing: Transforming a flat sheet into a three-dimensional shape using a punch and die.
Welding
Welding joins different sheet metal components together. Common welding methods include MIG welding (Metal Inert Gas), TIG welding (Tungsten Inert Gas), and spot welding.
MIG Welding: Uses a consumable wire electrode and inert gas for welding.
TIG Welding: Uses a non-consumable tungsten electrode and inert gas for precise welding.
Spot Welding: Joins metal sheets by applying pressure and heat at specific points.
Assembly:
Assembly involves combining different fabricated parts through welding, fastening, or other methods to create the final product.
Finishing:
Finishing processes enhance the aesthetics and functionality of the sheet metal product. Moreover, this may include deburring, grinding, sanding, painting, or coating.
Deburring: Removes sharp edges and burrs.
Grinding and Sanding: Smoothens surfaces.
Painting and Coating: Adds protective layers or decorative finishes.
Laser Engraving or Etching: Uses lasers to mark or engrave patterns, logos, or identification on metal surfaces.
Quality Control:
Quality Control Involves inspection and testing to ensure that fabricated components meet specified tolerances and quality standards.
Other Technologies Involved:
During the whole fabrication process, there may some steps that involve Computer-Aided Manufacturing (CAM) and CNC Machining. CAM refers to designing and programming processes that enable precision and accuracy in sheet metal fabrication. CNC Machining is to utilize computer numerical control (CNC) machines for precise cutting, drilling, and milling operations on sheet metal. And some factories may introduce robotics and automated systems for material handling, loading, and unloading processes, which is also a part of production line automation. With the technology development, the use of rapid prototyping technologies and 3D printing for creating prototypes and small batches of sheet metal components is widely seen in fabrication process too.
Companies often employ these processes and technologies in a coordinated manner, allowing for the efficient and precise fabrication of sheet metal components. Advanced manufacturing technologies and automation have significantly contributed to the speed, accuracy, and flexibility of sheet metal fabrication processes.
Top One Tech Metal Factory generally follows the following steps for hardware customization requirements: customer needs assessment and communication→design drawing→metal material selection→laser blanking→bending→fitter→welding (there are three methods: manual laser, Gas Metal Arc Welding, Gas Tungsten Arc Welding) – polishing – inspection – packaging – shipping. To ensure the finished product quality, the factory will stick to the following steps: ① First article confirmation ② IPQC inspection (mobile inspector) ③ QC inspection before shipment
The advantage of Top One Tech Metal factory
The advantage of Top One Tech Metal factory is that it supports small batches and differentiated customization. Furthermore, we can do small batches with high precision. Because of the high mold opening cost and difficulty, most factories are not willing to do small batches. Moreover, The Top One Tech Metal factory is equipped with advanced manufacturing machines (5 laser cutting machines and many other advanced equipment imported from home and abroad) and nearly 40 outstanding engineers, we have the capabilities to do it. And differential small-batch customization service is also the development strategy and direction of the factory.
About Top One Tech
Founded in 2010, Top One Tech has been a professional OEM&ODM manufacturer specialized in the R&D, customization, production and sales services of touch screens, touch monitors and all-in-one touch computers that can be integrated with various machines that are used in multiple industries including casinos, banking, industrial automation, medical equipment, point-of-sale, retail and transportation, industrial equipment, KIOSKs, etc.
Top One Tech also has established a branch Top One Tech Metal to provide our customers with sheet metal product customization and production. We can design and produce metal cases, metal cabinets, metal brackets, metal parts, as well as whole metal machines like smart lockers, vending machines, kiosks, etc.
We accept small-volume customization requirements and we aim to grow with our customers hand in hand.
See Also : Our Products for Metal Equipment Cases
