Everything You Need to Know About Metal Fabrication

Metal fabrication is as old as human civilization. It has evolved due to technological advancements. Manufacturing industries rely heavily on metal fabrication and can not survive without it. Without this technique, we won’t be able to produce auto parts, electrical appliances, kitchen utensils, and even bridges. 

Before going into metal fabrication, it is important to understand what it is and how it works. This article will be your guide on everything metal fabrication. It will explain what metal fabrication is, common metal fabrication processes, and factors to consider when choosing a metal fabricator. 

What is Metal Fabrication

Metal fabrication is a critical aspect of manufacturing that creates parts out of metal raw material. The components can be as simple as fasteners or more sophisticated large machinery and equipment. The metal fabrication process is usually in three stages; designing, fabrication, and assembling. 

Designing entails creating a digital representation of the final part. Fabrication describes all types of machining and metal casting processes. The last assembly step involves arranging the components to make a whole using techniques like welding or fastening. Metal fabrication produces durable and strong parts that can last for years. Additionally, the techniques are flexible and one can create custom products according to a project’s needs. 

Common Types of Metal Fabrication Techniques

This section discusses the different techniques you can use to fabricate a metal raw material. 

CNC Machining

CNC machining is one of the most common process metal fabricators use. It is a subtractive manufacturing technique that gradually removes excess material from a metal stock to create the final part. This technique is computer-controlled and produces accurate and precise components. CNC is automated and controls a range of machinery and tools such as mills, lathes, and grinders. 

The following are the most popular CNC machining operations.

• CNC Milling

CNC milling uses a rotating cutting tool to shape a stationary workpiece. It is accurate and has a tolerance level as low as +/- 0.001 inches. There are different types of mills with the most sophisticated being a 5-axis CNC machining. It moves along five different axes to produce complex shapes and designs. 

• CNC Turning

Here, the turning tools are stationary while the workpiece rotates at a high speed. CNC turning is a precise and repeatable process. It is used for cylindrical and oblong-shaped parts. You can also use it for shapes with axial symmetries such as discs or cones. 

• Laser Cutting

Laser cutting is another type of CNC operation. It is a noncontact process that uses a focused laser beam to cut through a metal. Laser cutting is fast and produces narrow cuts. Additionally, the cuts are clean and may not require post-processing. 

• Plasma Cutting 

Plasma cutting uses an electrically conductive gas to melt and vapourize a metal material. It works mainly with conductive metals such as aluminum and copper. Plasma cutting produces high-quality cuts with a small heat-affected zone. 

Sheet Metal Fabrication

Sheet metal fabrication describes a process of turning metal sheets into useful products and components. It involves forming, cutting, bending, and assembling sheets of steel and aluminum into different shapes. There are different techniques under sheet metal fabrication and they are usually not used alone. These techniques fall under three main categories; cutting, forming, and joining

• Cutting

Cutting encompasses many processes that use sharp tools to overcome the shear strength of a metal and result in a cutting action. The applied force must be greater than the metal strength to separate it. Cutting may involve shearing or punching holes and cutouts into metal sheets with a die. Blanking and sawing with a sawtooth tool also comes under cutting.

• Forming

Forming includes different techniques that shape a metal sheet without adding or removing any material. The metals remain in their solid state without losing their structural integrity. It involves using external forces to bend or curl parts of the metal sheet to remove burrs and produce smooth edges. Other common forming techniques are rolling, stamping, and hemming.

• Joining

Joint employs various operations to hold two or more metal sheets together. There are two main joining processes; welding and riveting. 

• Welding uses heat to fuse metal parts. SMAW, MIG, and TIG welding are the most common types.
• Riveting is a nonpermanent process that uses different types of rivets to firmly hold metal pieces. 

Metal Casting

Metal casting is the process of pouring molten metal into a mold that contains a negative impression of the final shape. The metal takes the shape of the mold as it cools and solidifies. Metal casting is versatile and can work with different metal alloys. It is capable of producing complex shaped parts with intricate designs. 

• Die Casting

Here, the molten metal is forced into a steel mold cavity under pressure where it cools and hardens. Die casting can either use low or high pressure based on requirements. This process is fast and one can reuse the mold. 

• Investment Casting

Investment casting uses a ceramic or plastic shell made around a wax pattern as the mold. You remove the wax by melting it before pouring the molten metal. It is suitable for small structures and produces a smooth surface. 

• Sand Casting

Sand casting uses sand as the mold material. Inorganic binding agents hold the sand particles together firmly. The sand mold is not reusable because you have break it open to remove the final casting. Sand casting has a low cost and is suitable for metals with low plasticity such as cast iron. 

3D Printing

3D printing is an additive manufacturing technique that produces a 3-dimensional object. You carry out this process using a digital file to create the part in layers on the printing bed. This technique offers more design freedom and is suitable for rapid prototyping. It is cost-effective and results in less material waste.

Direct Metal Laser Sintering (DMLS) and Selective Laser Melting (SLS) are the two most common metal additive manufacturing processes. They both operate on the same powder bed fusion printing principle. As the metal powder reaches the bed, a fiber laser completely melts it and traces out the cross-sectional area to produce the final part. Note that SLS uses a laser with a higher power which makes it faster than DMLS. 

Common Materials for Metal Fabrication

There are different types of metals one can easily fabricate using various techniques. They have different properties and benefits which influence their use. The following are the most common fabrication metals 

Aluminum

Aluminum is one of the most abundant metals on earth. It is strong, lightweight, and forms a compact oxide layer which makes it resistant to corrosion. Furthermore, aluminum is ductile and with a high thermal and electrical conductivity. Note that this metal is hardly used alone. You will find it alloyed with other metals such as silicon and magnesium to enhance its properties. 

Applications: Aircraft wings and fuselage, satellite dishes, and cookware.

Zinc

Zinc is a slightly brittle metal with a bluish-white appearance. It is ductile and malleable when heated slightly about 100 degree celsius. Pure zinc is nonreactive with remarkable corrosion resistance. Just like aluminum, you will mostly find zinc as an alloy.

Applications: Household fittings, marine vessels, and architectural structures.

Steel

Steel is an alloy containing mainly iron with less than 2% carbon. Steel has a high strength and is easily machinable. Furthermore, it is durable and does not break down under stress. There are different grades of steel available with unique chemical compositions and properties.

Applications: Medical devices, sports equipment, rails, and bridges.

Stainless Steel

Stainless steel is a type of steel metal. It contains iron alloyed with an average of 15% chromium, 5% nickel, and other metals. Stainless steel has an attractive appearance and is durable and temperature-resistant. It is environmentally friendly and easy to maintain. Stainless steel is further divided into five subtypes: martensitic, ferritic, austenitic, duplex, and precipitation hardened.

Applications: Kitchen utensils, medical equipment, aerospace parts, and components of windows and doors.

Bronze

Bronze is an alloy containing primarily copper, 12% tin, and other metals and nonmetals. It has a reddish-brown color with a great finish. Bronze metal is a good conductor of heat and electricity and its exceptional ductility makes it popular. Furthermore, the presence of tin makes bronze malleable and easy to cast into various shapes. Bronze is non sparking and can survive in corrosive environments.

Applications: Tools, architecture, car bearings and bushings, and components of food processing machines.

Brass

Brass is a nonferrous metal with a dull gold color. It contains a high percentage of copper and zinc with traces of iron, tin, and lead. Brass is malleable and easy to machine. Its inherent antibacterial properties make it stand out. Brass kills a wide range of microorganisms that come in contact with it. However, this metal is relatively expensive.

Applications: Valves, door handles, and hinges, marine engines, musical instruments, and pipes. 

Copper

Copper is a pure metal with a reddish-brown color. It is ductile and comes with a medium hardness that can be increased by cold working. Furthermore, copper has a remarkable electrical and thermal conductivity. It prevents the accumulation of unwanted organisms when used for marine structures. You would often find copper alloyed with other metals like zinc and tin.

Applications: Marine components, piping systems, and electrical equipment. 

Iron

Iron is a lustrous metal and has a gray-white color. It is malleable, ductile, and highly reactive. It does not exist alone and you will find it as magnetite, hematite, goethite, limonite, and pyrite. Iron is soft and ferromagnetic. It is usually alloyed with other elements such as carbon, chromium, silicon, nickel, and manganese.

Applications: pipes and pumps, bicycle chains, bridges, and cutting tools.

Titanium

Titanium has a silvery-white color with a high strength-to-weight ratio. It is nonmagnetic, ductile, and has a low coefficient of heat expansion. Titanium is biocompatible and does not break down when in prolonged contact with bodily fluids. There are different grades and alloys of titanium with unique properties.

Applications: Medical implants and joint replacements, jewelry, heat exchangers, and aerospace landing gears.

Factors to Consider When Choosing Metal Fabricators

Using a reliable metal fabricator makes all the difference. With many options available, it can be overwhelming when choosing the best. The following are some factors you should look out for when making your choice. 

Certified Manufacturers

Always check if the manufacturer has relevant certifications such as ISO9001, IATF 16949, ISO 4001, AS 9001, and ISO 13485. Some certifications are broad while some are very specific. Certification is proof that companies meet the highest quality standards and deliver the best products to their customers. They continuously look for ways to improve their product and services. Working with certified manufacturers results in fewer failures and prevents waste and recalls. 

Fabrication Capabilities and Range

The technology and equipment a manufacturer has is a vital consideration. Ensure that the metal fabrication tools and equipment are up to date and properly maintained. Furthermore, the company should make provisions for inspection techniques such as coordinate measuring machines to check for the accuracy of the final part.  They must also have a wide range of finishing options to suit your machining needs.

Fabrication Cost

You should also consider the total cost of manufacturing. You do this by requesting a quote. A quotation contains the material, labor, and total costs you would incur. However, you should always prioritize quality over cost. The most affordable manufacturer may not produce quality products that meet your standards. There should be a balance between cost and quality.

Lead Time

The estimated lead time is also important. Getting your products to market on time will give you a competitive edge. Check for factors that can affect lead time such as logistics and team size. Delays in procuring raw materials or frequent stockouts will prolong the manufacturing time. Additionally, a metal fabricator with a small team may be unable to meet up with the agreed time. 

Experience and Expertise

Practical and hands-on experience are important in metal fabrication. Ensures that the production team is skilled and can deliver high-quality work. If possible, visit the metal fabrication shop and have physical interaction with the individuals you want to work with. Check their success stories, understand the previous customers they’ve served, and be sure they can handle your project. 

Customer Service

Look for metal fabrication companies that place their customers’ needs first. Ensure they have a customer service team on standby to help with issues when they arise. Work with manufacturers that offer warranty under specified conditions. They should make provisions for reworking or refunds if the product’s quality is below the initial agreement. 

Effective Communication 

Reputable manufacturers will take you through the entire metal fabrication process. Your input should be relevant during the designing, prototyping, and manufacturing phases. There should be adequate communication in cases when they want to make changes for any reason. You should get a full breakdown of the operation. 

Zintilon for Your Precision Metal Fabrication Services 

Are you looking for a reliable metal fabricator? Then, you are in the right place. Zintilon is a one-stop manufacturer that provides high-quality parts at a competitive price. We offer all our services from designing and DFM analysis to prototyping and full production under one roof. 

We are committed to quality and the relevant certifications we hold are proof. Zintilon is proud to be IATF 16949:2016, ISO 9001:2015, ISO 14001:2015, ISO 13485:2016, and AS9100D certified. We have been in the industry for over 20 years and have offered smooth experience from design to reality for more than 3000 customers. Our engineers and machinists are experienced and can meet all your manufacturing needs. 

Our services include rapid prototyping, precision part manufacturing, and high-quality surface finishing. We are vast and use a wide range of technologies such as CNC machining, 3D printing, vacuum casting, and injection molding. To get started, request a quote and we will get back to you immediately. 

Conclusion

Metal fabrication will continue to evolve and shape the world in exciting ways. The future of metal fabrication lies in automation and the use of robotics for hazardous tasks. It will also entail Internet of Things (IoT) to control the equipment and enable remote monitoring. What is metal fabrication? How can I find a reliable metal fabricator? We hope this article has answered all your questions. Feel free to contact us for further inquiries and clarifications.

FAQ

What industries use metal fabrication?

Metal fabrication is a vital part of many manufacturing industries. Some of these industries include aerospace, automotive, medical, construction, marine, energy and electrical. 

What is the difference between metal fabrication and machining?

Metal fabrication encompasses many operations that fall under machining and casting. It involves making functional components from metal raw materials. Machining falls under metal fabrication and it describes the process of gradually removing excess material from a metal stock to create the final product. 

What are the safety risks associated with metal fabrication?

Metal fabrication can lead to some hazards if not properly managed. It can cause cuts, burns, chemical spills, and other health issues. To avoid this, the operator should wear appropriate PPEs every time.