The sheet metal manufacturing guide covers a variety of technologies, materials, and applications
- The sheet metal manufacturing guide covers a variety of technologies, materials, and applications
- What is sheet metal processing and how does it manufacture precision metal parts?
- Sheet metal manufacturing involves a variety of different processes.
- Commonly used materials, applications and precision in sheet metal work
- Surface finishing processes and advantages for sheet metal parts made of different materials
- Industries and applications and corresponding manufacturing processes
- Future Trends in Sheet Metal Manufacturing Technology
- Elimold is your trusted sheet metal fabrication and design company.
- in conclusion
Sheet metal fabrication is a manufacturing process for producing durable metal parts . Sheet metal parts are essential in various industries. Sheet metal processing technology allows metal sheets or bars to be processed into complex components . This process involves cutting, bending, and other forming techniques, each of which is crucial to the final product’s shape.
A successful sheet metal part requires consideration of factors such as thickness, strength, and corrosion resistance before manufacturing . We will delve into the intricacies of sheet metal fabrication, focusing on the technical principles behind cutting, bending, and other important forming processes. This blog post aims to help you gain a comprehensive understanding of sheet metal fabrication, from the initial selection of sheet metal type to the final precision machining that creates high-quality metal parts.
What is sheet metal processing and how does it manufacture precision metal parts?
Sheet metal processing is a comprehensive cold working process for metal sheets. It uses methods such as shearing, stamping, cutting, bending, and welding to shape and size metal sheets into desired dimensions, and is widely used in many industries. Thin metal sheets or bars are the basic materials for metal processing, easily processed into various different parts. The main manufacturing process involves the sheet metal first being hot-rolled into a roughing mill, becoming thinner and longer, which is crucial for precision sheet metal processing. A finishing mill further refines the thinner sheet. After cooling and coiling, it can be cut and bent. This method ensures high-quality sheet metal parts required for a wide range of designs and applications. From simple sheet metal to complex metal products, the versatility and adaptability of sheet metal materials in the manufacturing field are fully demonstrated.
Sheet metal manufacturing involves a variety of different processes.
The advantage of sheet metal lies in its versatility and adaptability to a wide range of applications. From cutting to bending, each step is designed to utilize different techniques to complete the fabrication of sheet metal. This maintains the integrity of the metal while showcasing the exquisite craftsmanship required to transform it into a high-quality component. Below are the various processes involved in sheet metal manufacturing.
Sheet metal cutting process
Below, we will explore the complexities of cutting techniques, a crucial aspect of sheet metal fabrication. We will understand the principles and applications of cutting, and when to use specific cutting processes to enhance the processing capabilities and design of sheet metal parts.
| Cut | Shearing is a process of cutting metal using two blades (one fixed, one moving). It is primarily used for straight-line cutting of sheet metal parts. This method can efficiently handle sheet metal of a certain thickness. It is the foundation of custom sheet metal processing, enabling the rapid and efficient cutting of large pieces of metal into smaller, usable sizes without altering the sheet metal’s properties. |
| Laser cutting | Laser cutting uses a high-powered laser beam, focused by a lens or mirror, to melt, burn, or vaporize material. It’s a precise method for sheet metal fabrication, capable of cutting sheet metal from thin to medium thicknesses. The advantages of laser cutting include high precision, the ability to cut a variety of materials, and the capacity to process complex shapes and fine details. This method improves the sheet metal design process, enabling complex patterns and precise cuts without mechanical contact. |
| Waterjet cutting | Waterjet cutting uses a high-pressure stream of water, usually mixed with an abrasive, to cut materials. It is particularly suitable for cutting thin metal sheets and does not produce heat deformation, making it ideal for materials sensitive to high temperatures. This technology is also versatile and capable of cutting thick metal sheets. |
Sheet metal bending forming process
Metal bending is a key process in sheet metal processing, changing the shape of metal to meet specific design requirements. Manufacturers achieve precise bending through processes such as bending machines, roll bending, and folding, thereby improving the functionality and aesthetics of sheet metal products.
| Bending machine forming | Bending machine forming is the cornerstone of sheet metal forming technology. It utilizes a bending machine to bend metal sheets. This method can adapt to sheets of various thicknesses, and through a series of operations, the bending angle can be adjusted from acute to obtuse angles, and even complex shapes, achieving various bending effects. The flexible adjustment of sheet thickness and bending angle makes it an ideal choice for customized sheet metal products. |
| Roll bending | Roll bending is another sheet metal bending technique that uses a set of rollers to bend metal into an arc shape. Roll bending is ideal for creating cylindrical or gentle curves in products; simply place the sheet metal between the rollers. Roll bending is particularly suitable for large sheet metal forming and is a key process for manufacturing components such as pipes, tanks, and other curved metal structures. |
| Bending | Bending is a precision sheet metal forming process that clamps a workpiece between a die and a punch, then bends the metal in the desired direction. It is particularly suitable for sharp bends and complex geometries, where the accuracy of sheet metal thickness and bending position is crucial. Bending technology is applied in complex designs and assemblies, where precise joins of sheet metal are essential. This highlights the versatility and precision of sheet metal processing in manufacturing intricate and complex structures. |
Welding processes commonly used in sheet metal manufacturing
| MIG welding (gas shielded metal arc welding) | MIG welding is highly adaptable and suitable for various types and thicknesses of metal sheets. It is fast and efficient, making it suitable for long-term processing operations. |
| TIG welding (Gas-shielded tungsten inert gas welding) | TIG welding provides high-quality joins for various types of sheet metal, especially thin sheets. TIG welding is favored for its precision and controllability, which are crucial in sheet metal fabrication (referring to precision machining projects). |
| spot welding | Primarily used in the metal stamping and automotive industries, spot welding connects overlapping metal sheets without affecting the overall thickness. It is fast, efficient, and suitable for mass production. |
| Laser welding | A cutting-edge technology, often combined with laser cutting of sheet metal, offers high precision and speed. It is ideal for complex joins or fragile materials requiring extremely high temperature control. |
| riveting | In addition to welding , riveting is a traditional and robust method of joining metal parts together using metal pins or rivets. |
Sheet metal stamping
Sheet metal stamping is a cold forming technology that uses stamping presses and dies to process raw materials into various shapes. This process is applicable to a wide range of sheet metal materials. Stamping can often be a combination of complex cutting and forming techniques to obtain complex parts in relatively short operations. It includes bending, punching, embossing, and flanging to create a broad range of products.
Metal stamping is cost-effective. The process is quick, requires fewer tools and less labor time, and the maintenance costs of stamping dies are relatively low, which contributes to the overall cost reduction. Automating metal stamping is also easy. Therefore, proper programming of the metal stamping press will ensure consistently high-quality precision parts and repeatability. However, the disadvantage of stamping is the increased cost of the press. If design changes are needed during production, changing the dies can be difficult.
Edge binding
Hemming involves rolling the edge of a sheet metal piece onto itself to create a two-layered area. It typically occurs in two stages. The first stage involves bending the sheet metal and shaping it into a V-shape. The second stage involves removing the material and placing it into a flattening die. This process flattens the hem to provide the desired shape. Hemming is very effective for reinforcing part edges and improving the part’s appearance. The accuracy of this process contributes to obtaining components with excellent surface quality. However, material deformation occurs during this process, resulting in dimensional changes.
Roll
Sheet metal rolling is the process of passing metal parts through a pair of rollers to reduce material thickness or achieve a uniform thickness. The rollers rotate continuously to generate compressive forces that plastically deform the workpiece.
Sheet metal manufacturing processes have two main rolling processes: hot rolling and cold rolling. Hot rolling occurs above the material’s recrystallization temperature, while cold rolling typically occurs at room temperature. Common applications for rolled sheet metal include tubing, stampings, discs, wheels, and rims.
Rolling is fast and efficient, making it suitable for mass production. The process can be designed to manufacture parts with tight tolerances and complex cross-sectional profiles. However, metal rolling requires a high initial investment, making it more suitable for large-scale production.
Punching
Punching also uses shearing force to create holes in a metal sheet. However, in this case, the material removed from the hole is scrap, while the material remaining on the die is the final component. Punching helps create cuts and holes of various sizes and shapes. This process is faster than blanking and can produce clean, precise parts in a short time. Since no heat is involved, there is no risk of thermal changes in the workpiece. However, punching preparation can be very time-consuming because the punching tool and die need to be precisely matched.
Commonly used materials, applications and precision in sheet metal work
Laser Cutting
| Material | Typical Thickness Range | Achievable Tolerance | Common Applications |
| Carbon Steel | 0.5–20 mm | ±0.05–0.10 mm | Structural brackets, frames, automotive panels |
| Stainless Steel (304/316) | 0.5–15 mm | ±0.05–0.08 mm | Medical housings, food equipment, enclosures |
| Aluminum (5052/6061) | 0.5–12 mm | ±0.05–0.10 mm | Electronics housings, aerospace panels |
| Copper | 0.3–6 mm | ±0.03–0.05 mm | Busbars, heat sinks |
| Brass | 0.3–8 mm | ±0.03–0.05 mm | Decorative panels, connectors |
CNC Punching
| Material | Typical Thickness Range | Achievable Tolerance | Common Applications |
| Mild Steel | 0.8–6 mm | ±0.10–0.20 mm | Electrical cabinets, mounting plates |
| Galvanized Steel | 0.8–5 mm | ±0.10–0.20 mm | HVAC ducts, outdoor enclosures |
| Aluminum | 0.8–4 mm | ±0.10–0.15 mm | Control panels, covers |
| Stainless Steel | 0.8–4 mm | ±0.10–0.15 mm | Equipment panels |
Press Brake Bending
| Material | Typical Thickness Range | Angular / Linear Accuracy | Common Applications |
| Carbon Steel | 0.8–12 mm | ±0.5° / ±0.20 mm | Frames, brackets |
| Stainless Steel | 0.8–10 mm | ±0.5° / ±0.15 mm | Enclosures, supports |
| Aluminum | 0.8–8 mm | ±0.5° / ±0.15 mm | Lightweight housings |
| Copper | 0.5–5 mm | ±0.5° / ±0.10 mm | Electrical components |
Stamping / Progressive Die
| Material | Typical Thickness Range | Achievable Tolerance | Common Applications |
| Low-Carbon Steel | 0.3–3 mm | ±0.05–0.10 mm | Automotive body parts |
| Stainless Steel | 0.3–2 mm | ±0.05–0.08 mm | Precision brackets |
| Aluminum | 0.3–3 mm | ±0.05–0.10 mm | Consumer electronics parts |
| Brass | 0.2–2 mm | ±0.03–0.05 mm | Electrical terminals |
Deep Drawing / Forming
| Material | Typical Thickness Range | Achievable Tolerance | Common Applications |
| Low-Carbon Steel | 0.5–3 mm | ±0.10–0.20 mm | Automotive shells, housings |
| Stainless Steel | 0.5–2.5 mm | ±0.10–0.15 mm | Kitchenware, medical containers |
| Aluminum | 0.5–3 mm | ±0.10–0.20 mm | Aerospace and consumer housings |
Surface finishing processes and advantages for sheet metal parts made of different materials
| Base Material | Surface Finishing Process | Primary Purpose | Typical Applications |
| Carbon Steel | Powder Coating | Corrosion protection, aesthetic finish | Enclosures, brackets, frames |
| Electroplating (Zinc, Nickel) | Corrosion resistance, wear protection | Fasteners, structural panels | |
| Black Oxide | Mild corrosion resistance, reduced glare | Internal machine components | |
| Phosphating | Paint adhesion, corrosion resistance | Automotive body parts | |
| Painting (Wet Spray) | Appearance, corrosion protection | Industrial panels, housings | |
| Stainless Steel | Brushing / Polishing | Surface aesthetics, cleanliness | Medical equipment, appliances |
| Electropolishing | Smoothness, corrosion resistance | Food & medical components | |
| Passivation | Enhance corrosion resistance | Precision and hygienic parts | |
| Aluminum | Anodizing (Type II / Type III) | Corrosion resistance, hardness | Electronics, aerospace panels |
| Powder Coating | Appearance, weather resistance | Automotive and architectural panels | |
| Chromate Conversion (Alodine) | Corrosion protection, paint adhesion | Aerospace sheet parts | |
| Brushing / Sandblasting | Surface texture, appearance | Decorative panels | |
| Galvanized Steel | Powder Coating | Enhanced corrosion resistance | Outdoor enclosures |
| Painting | Color, additional protection | HVAC panels | |
| Copper | Electroplating (Tin, Nickel) | Oxidation prevention, solderability | Busbars, electrical parts |
| Clear Coating / Lacquering | Oxidation protection | Decorative and electrical parts | |
| Brass | Polishing | Decorative appearance | Nameplates, trims |
| Clear Coating | Tarnish prevention | Architectural and consumer parts | |
| Titanium | Anodizing | Color coding, corrosion resistance | Aerospace and medical parts |
| Nickel Alloys | Passivation | Corrosion resistance | Chemical processing equipment |
Industries and applications and corresponding manufacturing processes
| Industry | Typical Sheet Metal Applications / Components | Commonly Used Manufacturing Processes |
| Automotive | Body panels, brackets, chassis reinforcements, battery trays | Stamping, laser cutting, press brake bending, spot welding |
| Aerospace | Fuselage panels, brackets, heat shields, ducts | Laser cutting, CNC punching, precision bending, riveting |
| Electronics & Electrical | Enclosures, control cabinets, server racks, shielding covers | Laser cutting, CNC punching, bending, powder coating |
| Industrial Equipment | Machine frames, guards, panels, housings | Laser cutting, bending, welding, surface coating |
| HVAC & Refrigeration | Air ducts, vents, housings, fan blades | Shearing, punching, roll forming, spot welding |
| Construction & Architecture | Facade panels, roofing, cladding, handrails | Laser cutting, bending, roll forming, welding |
| Medical Devices | Equipment housings, instrument covers, trays | Laser cutting, precision bending, polishing, passivation |
| Energy & Power | Electrical cabinets, transformer enclosures, mounting frames | Laser cutting, punching, bending, corrosion-resistant coating |
| Telecommunications | Network cabinets, racks, antenna housings | Laser cutting, CNC punching, bending, painting |
| Consumer Electronics | Device housings, brackets, internal shields | Precision stamping, laser cutting, bending, anodizing |
| Agriculture & Heavy Machinery | Protective covers, structural panels, guards | Laser cutting, bending, welding, painting |
| Rail & Transportation | Car body panels, interior structures, brackets | Stamping, laser cutting, bending, spot welding |
| Defense & Security | Equipment enclosures, protective panels | Laser cutting, forming, welding, special surface treatments |
| Food Processing | Equipment panels, conveyor covers, housings | Laser cutting, bending, welding, electropolishing |
| Renewable Energy | Solar panel frames, inverter housings, battery enclosures | Laser cutting, bending, welding, powder coating |
Future Trends in Sheet Metal Manufacturing Technology
In exploring advanced technologies and future trends in the field of metal processing, we have discovered innovative bending methods that improve the precision and efficiency of metal forming. These methods are constantly evolving to address the complexity of various sheet metal processing materials and parts, thereby enabling more sophisticated applications.
Metal 3D printing is at the forefront of these advancements. It is revolutionizing the way we use sheet metal. This technology can create custom parts with complex, high-strength structures by stacking thin sheets of metal. Its potential impact is enormous, promising to accelerate the production of customized sheet metal parts and reduce costs, and enabling designs previously impossible through traditional methods.
Furthermore, the equipment used in sheet metal factories can improve production efficiency, cost, and quality control by integrating advanced robotics and artificial intelligence. Automated equipment can also simplify processes such as stamping, cutting, and bending, improving efficiency and precision. This shift towards automation optimizes sheet metal processes and can also improve operator safety and working conditions.
Elimold is your trusted sheet metal fabrication and design company.
At Elimold, we not only possess expertise in all of the aforementioned skills, but we also have a professional technical team that provides leading sheet metal manufacturing services, producing high-quality parts for you at highly competitive prices. As an ISO9001:2015 certified company, we focus on building a robust quality management system to provide reliable services to our clients.
Our team of experts has experience performing Design for Manufacturability (DFM) analyses to improve your designs. We are not just a manufacturer, but also a partner, committed to providing comprehensive support and professional advice to our clients to ensure that designs reduce manufacturing costs while still meeting high-quality standards. If you have a design model that needs to be manufactured, please upload it to us immediately, and we will provide you with a quote right away.
in conclusion
Understanding the complexities of sheet metal fabrication, including cutting, bending, and other techniques, is crucial. Sheet metal processing is a multifaceted process essential for transforming flat metal sheets into desired shapes and products. As technology advances, sheet metal production costs continue to evolve, prompting ongoing exploration and development in this field. Let’s delve into these advancements, enrich our knowledge, push the boundaries of sheet metal processing, and create innovative solutions.