Complete Guide to Custom Sheet Metal Bracket Manufacturing

Over the years, the custom manufacturing of key mechanical support components has undergone several transformations. With advancements in heavy machinery design, support components such as sheet metal brackets have also required corresponding improvements. In the past, most metal enclosure support structures for machinery and electronic products used basic designs, but in recent years, due to innovations in support component design, custom manufacturing of different sheet metal bracket products according to market needs has become particularly important. Nevertheless, most support brackets for metal enclosures of machinery and electronic products are still made of sheet metal. Custom manufacturing of such components ensures design precision and compliance with mechanical requirements. Understanding the manufacturing process of sheet metal brackets is crucial, therefore this article will be of great benefit to you.

What are sheet metal bracket parts?

Sheet metal brackets refer to metal structural parts in the middle or supporting parts of a product’s overall structure, used for installing or assembling different components. Typically, the thickness of the metal sheet ranges from 0.3 to 6 millimeters, but some sheets can reach 20 millimeters. Depending on the complexity of the design, brackets can be shaped using techniques such as laser cutting, bending, punching, and embossing.

Most supports are functional, designed to connect and support the overall structure. They can also be decorative and ornate, ranging from intricate machined decorative features to gold plating.

Design Considerations

Our custom metal bracket projects are typically designed according to specific client requirements. Therefore, selecting the best design for your project is a crucial step in the manufacturing process of custom metal bracket components. You need an excellent design that achieves the intended purpose. Whether you wish to use a metal bracket as a support structure, final structure, or intermediate structure, it must meet the necessary safety standards.

Therefore, before beginning the design phase of a sheet metal bracket, you need to consider several factors, including material strength, load-bearing capacity, application, mounting method, and bracket location. These key factors will affect the overall suitability of the manufactured bracket. Another important factor to consider is the thickness of the sheet metal used to manufacture the metal bracket. Thickness is crucial for determining the structural strength and failure stress of the component.

Manufacturing technology of sheet metal bracket parts

Brackets can be manufactured in various ways, such as casting or CNC machining. However, the best method for making simple brackets is sheet metal fabrication. One of the most common processes in sheet metal fabrication is bending. Sheet metal bending can process metal parts at angles up to 120°, which is a crucial factor in manufacturing sheet metal brackets, as almost all brackets involve at least one bend. If the sheet metal bracket part you need is quite complex, other sheet metal processes may be necessary. Additionally, before any bending, the metal sheet is cut to size using machines such as laser cutters or plasma cutters. Holes can be punched into the bracket (for screws), and welding may be required to add gussets or other features. Besides sheet metal processes, CNC machining can be used to add more complex features to brackets, especially for custom designs of non-standard parts.

Metal forming method for bracket manufacturing

Before manufacturing sheet metal brackets, the raw sheet metal is typically cut to the required length and width using cutting processes such as laser cutting or plasma cutting. Then, depending on the complexity of the design, various forming methods are employed. Below are the sheet metal manufacturing processes we commonly use when manufacturing metal brackets.

Molding method	describe
bending	Deform metal along a straight line to form an angle or curve.
Laser cutting + bending	First, a laser cut is used to create the outline, which is then bent into the final shape.
stamping	A mold that forms shapes, cuts, or holes by pressing in a sheet of metal.
Deep drawing	It pulls the metal sheet into the mold, forming a deeper cup shape.
Hydraulic forming	High-pressure hydraulic oil shapes the sheet metal in a mold.
Roll forming	Metal sheets are continuously formed using rollers.
punching	It creates holes or specific cuts by pressing a punch.
Hidden disappearance	It uses punches and die settings to cut flat and predefined shapes.

Common bracket types that can be produced by sheet metal manufacturing processes

Many types of metal brackets can be manufactured using sheet metal fabrication and other processes. The types of brackets vary depending on the application and the object they are intended to support. Below are some of the bracket part types we frequently manufacture.

L-shaped metal bracket	L-shaped brackets are the most common type of profile. As the name suggests, the profile shape conforms to the letter “L”. These custom sheet metal brackets are suitable for mounting vertical or horizontal structures. The mounting portion or mounting holes are located on the L-shaped cross-section.
Z-shaped metal bracket	Making a Z-shaped bracket requires two bends on the same side of the metal plate. That is, the first bend faces inward, and the second bend faces outward. It is perfect for mounting offset or parallel items.
U-shaped metal bracket	It is U-shaped with protruding parts on both sides. In most cases, the protruding parts have holes or mounting parts.
Angle brace metal bracket	Although the main structure of the gusset plate bracket is similar to that of the L-shaped metal bracket, it has additional reinforcement on opposite sides. Typically, the reinforcement consists of two triangles welded to both sides.
biased metal bracket	The mounting method for offset brackets is similar to that of Z-type brackets. However, this type of bracket is more suitable for mounting on parallel surfaces. Similarly, you can use these metal brackets like the U-type design.
Metal T-shaped bracket	These brackets are T-shaped and suitable for various applications. Mounting holes are located on the surface of the T-shaped bracket. The T-shaped metal brackets are versatile and allow for easy expansion of structural designs.
Flat metal bracket	They are made up of flat, straight metal strips. Depending on the design, they may have mounting holes or hooks.
Metal tripod	These are unique L-shaped metal supports. However, one section has a sturdy rectangular structure attached to the base section.

Material selection and considerations for sheet metal bracket parts

Material selection is the first step in manufacturing metal support components and varies depending on the required application. Key mechanical properties, such as strength, stiffness, and toughness, are essential to withstand the loads applied to the support. Corrosion prevention is also a critical factor to consider to prevent material degradation.

Furthermore, cost is a major limiting factor for both material and manufacturing costs. Ductility and malleability are essential properties that materials must possess to allow for easy molding into the desired shape. Especially for weight-sensitive applications, a high strength-to-weight ratio is crucial. Heat resistance and the ability to withstand external environmental conditions are also equally important factors in material selection. Common materials and considerations for custom-manufacturing sheet metal brackets :

Commonly used materials for manufacturing metal bracket parts

steel	Steel has high strength and durability, making it ideal for heavy-duty applications.
aluminum	In applications where the load is not heavy, aluminum is an ideal choice, especially when weight is a consideration.
Stainless steel	Stainless steel has corrosion resistance and, due to its excellent mechanical properties, higher strength, and ability to withstand harsh environmental conditions.
galvanized steel	Zinc plating is a process that coats a metal surface with a layer of zinc, which helps prevent corrosion.
copper	Copper brackets are known for their excellent thermal and electrical conductivity. They have a bright surface, are durable, safe, and easy to cut.
brass	Brass brackets are corrosion-resistant, easy to cast, and heat-resistant. In addition, they have a smooth surface that does not easily lose its luster.

Key factors to consider when selecting support materials

Load capacity	Load-bearing capacity can be determined by estimating the maximum load the support needs to withstand. This will vary depending on the application scenario, and it is the first step in determining the support material, size, and shape.
Size and shape	After determining the load-bearing capacity, the design and shape of the support structure need to be carefully studied to ensure that it meets the application requirements. This includes steps such as topology optimization.
Installation method	Once the dimensions are determined, the next step is to determine the appropriate installation method based on the specific application scenario to ensure the bracket’s stability. These installation methods depend on the results of load-bearing capacity calculations.

Surface treatment process of sheet metal bracket parts

After manufacturing, the bracket requires fine surface treatment, which can be achieved using various processes. Some of these processes are listed below:

Powder coating	This process involves dry deposition of carbide layers onto the metal surface to achieve a high-quality surface treatment effect.
Spray paint	To prevent corrosion, spray painting is currently the most commonly used surface treatment method.
Anodizing	This process is relatively complex for support parts made of stainless steel , but it is very effective in preventing corrosion of aluminum supports and avoiding surface discoloration.
plating	This method involves plating a layer of metal such as zinc or chromium onto the surface of the support to achieve better surface finish and corrosion resistance.

Potential problems in manufacturing metal bracket parts

When developing custom sheet metal brackets, you may encounter some issues. Here are some common problems:

Tool wear	Tool wear can be caused by fatigue stress or continuous use. This can lead to deformation of the final product.
rebound	This is a phenomenon where a material reverts to its original state, which alters the stress-bearing area.
thinning	When sheet metal is excessively bent or shaped, the material becomes thinner, thereby reducing structural strength.
cost	Sometimes, cost is also a limiting factor that can hinder the manufacturing of sheet metal brackets, especially in the finishing stage, as anodizing and electroplating can be very expensive.

Why choose Elimold for your custom metal bracket projects?

Elimold provides comprehensive sheet metal fabrication services, including custom sheet metal brackets tailored to specific industrial needs. Our advanced metal manufacturing facility is equipped with laser cutting machines, tooling and stamping equipment, punching, and other facilities. We can manufacture your bracket designs precisely to your specifications and requirements. Our in-house engineering design capabilities allow you to quickly and easily refine designs, obtain quotes, and order manufacturable custom enclosures, panels, and parts, including brackets. If you want to design brackets quickly, Elimold is a great choice because it allows you to select your style, size, material, and surface finish, and then quickly customize it with the cutouts and fasteners you need.

in conclusion

Custom manufacturers around the world use a variety of technologies to create metal supports of different shapes. It’s a relatively simple process, but there are some bottlenecks to be aware of. The ductility of the material is crucial during manufacturing to prevent permanent damage to the supports. Adopting the latest manufacturing techniques is essential for technological advancement and can ultimately lead to design innovations.

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