Have you ever looked at a car and thought, “Wow! That’s beautiful.” Well, remember it doesn’t just happen on its own. Metal fabrication companies undergo rigorous design and procedures to ensure a product is aesthetically pleasing, functional, and secure per each industry’s regulatory standards.
So, how does this apply to your project?
It starts with your CAD (DXF) file, the software we use for our metal fabrication process, and the type of metal and finish you desire.
Let’s get into some basics and elaborate on this process from start to finish.
What is Metal Fabrication?
Metal fabrication is how companies create objects, machinery, and other items. It’s a process that involves many techniques, such as cutting, punching, bending, forming, and welding, to create your design.
The metal fabrication process begins with an engineered design. It is then taken to metal fabrication companies, like Steelway Laser Cutting. Which is then turned into a final product using the metal of your choice.
What Are the Different Types of Metal Fabrication?
The metal items we see daily, like vehicles, soda cans, and kitchen appliances, use various fabrication techniques.
The different types of metal fabrication techniques are:
- Cutting
- Bending
- Hemming
- Metal punching
- Metal forming
- MIG & TIG welding
- Milling
- Fastening
Let’s dig a little more into these metal fabrication processes.
Cutting Metal
CNC laser cutting machines are currently replacing traditional methods for cutting metal, such as sawing. The CNC laser cutting machine works with gases such as oxygen, nitrogen, carbon dioxide, and even helium to produce fine lines.
This process is quick, depending on the thickness of the metal.
Bending
Using machinery, most metals can bend to conform to the standards of your project.
Today’s impressive machines create smooth curves and sharp 90-degree angles. We can produce open or closed single-axis bends or curves using a rolling and forming method.
Hemming
Hemming is a process that involves rolling the edge of a metal shape for a smother yet stronger edge.
Different types of hems can provide you with an open space. Curling the metal creates a round edge (referred to as a barrel hem).
A round edge serves multiple functions. It can be used to eliminate sharp edges or serve a specific function. For example, to hold a pin for a door hinge.
Metal Punching
Metal punching uses a punch press machine to cut or punch holes into a metal sheet. It is often combined with a laser cutter to form a complex pattern.
Metal Forming
Metal forming is a fabrication technique that uses bending and rolling to create shapes.
Different types of bending techniques are used to form the shapes you desire. The most common is the V-die.
Welding
Metal welding is used to fuse multiple pieces of metal. Welding is an important part of the metal fabrication process.
MIG Welding, or Metal Inert Gas welding, uses an electric arc between electrodes in conjunction with a welding gun, a welding electrode wire, a power supply, a wire feed unit, and a shielding gas supply.
TIG Welding, or inert tungsten gas, uses tungsten electrodes to fuse metals.
Milling
Milling uses rotary cutters to remove unnecessary pieces of metal.
You can form a piece of metal by utilizing speed and pressure in varying directions on one or several axes. It is used for small, large, and even heavy-duty items.
Fastening
Fastening is the term used to bolt pieces of metal together. It’s used in the metal fabrication process and in assembling household objects.
Now that we understand the many types of fabrication that go along with metalwork let’s see what else we can apply to the process to ensure we have the best aesthetic with optimum functionality.
How Can You Optimize a Metal Fabrication Design?
When optimizing your metal fabrication design, we want to ensure it’s functional, sleek, and appealing. In the automotive industry, functionality and aesthetics are of extreme importance.
A car must meet rigorous regulatory safety standards and have marketable value. Therefore, even though the general population understands safety is paramount, we often shop with our eyes.
Furthermore, when completing a metal design, the finish is just as important to get your product into the world. With other industries, the finish allows for weather resistance and durability for a longer-lasting product.
Regardless, here are several ways to finish the product to optimize your design.
Finishing Touches to Your Sheet Metal Design
There are many ways to finish a design. Sometimes it’s done for aesthetics or protection, and sometimes, it’s for both.
The finishing treatments are alterations to the metal surface, or an added material applied to the metal.
These treatments are:
- Sandblasting
- Brushing
- Polishing
- Powder coating
- Plating
Additionally, each treatment has its strengths.
Sandblasting
This process is used to roughen and clean the metal surface by shooting abrasive material at the metal. This process is mainly used on stainless and carbon steel to remove impurities or before applying a coat of paint.
Brushing
Brushing uses abrasive brushes for scoring and cleaning metal surfaces. Sometimes used as a final finish on aluminum and stainless steel and often used as a finishing touch on appliances.
Polishing
Polishing gives you a glossy, shiny finishing touch. It’s often used on steel, aluminum, or copper.
Although often used as a finishing touch, it also allows for better plating.
However, applying paint to polished metal is not advisable.
Powder Coating
Powder coating is a way of painting metal that results in higher durability than conventional paint but often looks less clean than regular paint.
However, a thermoplastic or thermoset polymer is applied via electrostatic and cured with heat.
Plating
Plating is a finish with many purposes.
It can:
- impede corrosion
- enhance solderability
- toughen a surface
- prevents wear and tear
- decrease friction
- assist paint adhesion
The plating process differs according to what you need.
Steelway Laser Cutting Can Assist from Design to Installation
From concept to completion, Steelway Laser Cutting is based in King of Prussia, Pennsylvania and can help you through every step of the way.
First, start by sending us your design. We’ll review it quickly and send you a comprehensive quote with a full scope of work, proposal, and time frame.
Our quick turnaround ensures your design is finished and delivered with accuracy and speed. We understand your project is important. Let us guide you through the process.