Rapid Sheet Metal Manufacturing
1 off prototyping & 1000+ production parts
Sheet Metal Prototyping Fabrication
Zigitech’s custom sheet metal prototyping services offer a fast and cost-effective
solution for your projects. Services including bending, punching, cutting
standard gauge metal for both prototypes and low volume production runs. Sheet
metal fabrication produces durable, end-use metal parts with a wide selection of
materials and finishes that meet your specifications, for a variety of
industries like: Automotive, Medical device, Aerospace, electronics, energy and
robotics.
Advantages of Sheet Metal Fabrication
1 Material selection
Aluminum + Aluminum 1005, Aluminum 5052,
Aluminum 6061 , copper, stainless steel + Stainless Steel 202, Stainless
Steel 304, Stainless Steel 316, X10CrNi18.8
, steel and zinc
2 Finishing options
Bead blasting, anodizing, plating, powder coating and custom
finishes
3 Thickness options
Variety of gauges available
4 Durability
Sheet metal fabrication produces durable parts for
prototyping or end use
5 Scalability
Low setup costs mean low prices for large volumes
6 Turnaround
Parts delivered in just 5-10 days
What is
Sheet Metal Fabrication?
Sheet metal fabrication is a set of manufacturing processes used to turn sheet metal stock into
functional parts. The sheet metal is usually between 0.006 and 0.25 inches (0.015 and 0.635
centimeters) thick.
There are several processes that fall under the umbrella of ‘sheet metal fabrication’. These
include cutting, bending and punching, and can be used either in tandem or individually.
Sheet metal fabrication can be used to create either functional prototypes or end-use parts, but
end-use sheet metal parts generally require a finishing process before they are ready for
market.
Sheet Metal FAQ
Do I need laser cutting, water jet
cutting or plasma cutting?
The type of cutting machine used depends on the chosen material and the gauge of the
sheet, as well as factors like desired lead time and tolerances.
We know which projects need which equipment, so you don’t need to specify a particular
cutting machine.
Does it cost more to use multiple
sheet metal forming processes?
In general, a part that is cut, bent and punched will cost more than a part that is, for
example, just cut using a laser cutter.
However, most sheet metal parts demand a combination of forming processes, and this will
not increase the price by a drastic amount.
Is there a minimum order
quantity?
No. You can order a one-off prototype or 1,000+ units.
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How does sheet metal fabrication work?
Because thin sheets of metal are more malleable than a thick workpiece, they can be
manipulated using different processes.
These processes fall into three general categories:
In which the sheet metal is cut in various ways
In which the sheet metal is bent or formed
In which the sheet metal is joined to other components
Sheet metal fabrication Processes We Are Offering
1. Material Removal
Sheet metal fabrication uses material removal processes to remove, cut and puncture
the metal stock.
Laser cutting uses a laser to cut the sheet metal part. A high-power laser is
directed onto the sheet and intensified with a lens or mirror to a concentrated
spot. In the specific application of sheet metal fabrication, the focal length of
the laser varies between 1.5 to 3 inches (38 to 76 millimeters), and the laser spot
size measures around 0.001 inches (0.025 mm) in diameter.
- Part accuracies of better than 0.002 inches (0.05 mm)
- Kerf widths of 0.006 inches (0.15 mm) to 0.015 inches (0.38 mm)
- Material versatility
Laser cutting is more precise and energy-efficient than some other cutting processes,
but cannot cut through all kinds of sheet metal nor the very highest gauges
- Part accuracies of better than 0.002 inches (0.05 mm)
- Kerf widths of 0.006 inches (0.15 mm) to 0.015 inches (0.38 mm)
- Material versatility
A water jet cutter uses a high-pressure jet of water to penetrate the sheet metal.
Unless the metal is especially thin, the water is mixed with an abrasive substance
in order to cut through the solid material.
Since water jet cutting does not give off heat like laser or plasma cutting, the
process is particularly useful for metals that have a low melting point and might
otherwise deform. With water jet cutting, there is no heat-affected zone (HAZ),
and metals can be cut without changing their intrinsic properties.
- Part accuracies of better than 0.008 inches (0.2 mm))
- High cutting speed, e.g. 200 inches (5.08 meters) of 16-gauge mild steel per
minute
- Material versatility
Plasma jetting uses a jet of hot plasma to cut through the sheet metal. The process,
which involves creating an electrical channel of superheated ionised gas, is fast
and has a relatively low setup cost.
Thick sheet metal (up to 0.25 inches) is ideal for the plasma cutting process, since
computer-controlled plasma cutters are more powerful than laser or water jet
cutters. In fact, many plasma cutting machines can cut through workpieces up to 6
inches (150 mm) thick. However, the process is less accurate than laser cutting or
water jet cutting.
When the sheet metal needs to be punctured with holes, a designated punching machine
is generally more efficient than the above cutting methods. Punching involves
sandwiching the sheet between a punch and a die; when the punch moves into the die,
it forces a hole in the sheet. The process can also be used to form irregular
shapes, by making several small punches in series.
Most sheet metals can be punched, but the diameter of a round hole should generally
be larger than the thickness of the chosen metal.
2. Material Deformation
Sheet metal can be manipulated in other ways besides cutting. For example, it can be
bent into different shapes using special machinery.
Sheet metal bending is used to create V-shape, U-shape and channel shape bends using
a machine called a brake. Most brakes can bend sheet metal to an angle of up to 120
degrees, but the maximum bending force is dependent on factors such as metal
thickness and tensile strength.
In general, sheet metal must initially be over-bent, because it will partially spring
back towards its original position.
Stamping is another deformation process used to form sheet metal into a desired
shape. The process uses a stamping die — either mechanic or hydraulic — to press the
sheet metal into its new form.
Stamping is used on cold sheet metal, but the friction caused by the die causes the
metal to heat up to high temperatures. Individual stamping processes include, but
are not limited to.
- Coining, in which a pattern is pressed onto the sheet metal
part
- Curling, in which the sheet metal is deformed into a tubular
shape
- Hemming, in which sheet metal is folded on itself for extra
thickness
- Ironing, in which the sheet metal part is reduced in thickness
Sheet metal spinning is a deformation process — conceptually similar to pottery
spinning — that is used to create hollow parts with rounded features.
The spinning process involves manually or mechanically rotating a sheet metal blank
on a lathe and pressing it against a tool, which creates the interior shape of the
part. Spinning can be used to create shapes like hemispheres, cones and cylinders.
3. Material Assembly
Pieces of sheet metal that have been cut or bent can be joined together to form
complete sheet metal parts. These pieces can also be joined to components that are
not made from sheet metal.
A product may be designed so that several sheet metal parts can be fitted together
with joints, screws or other common methods.
This usually comes after the parts have undergone any required finishing processes.
Sheet metal parts sometimes need to be joined together using the process of welding,
which fuses components together with heat.
Sheet metal materials like aluminium and stainless steel have high weldability.
