Quick-Turn Sheet Metal Services

Laser Cutting – Punching

Punching is a machining technique for removing scrap metal from a sheet of raw metal. It entails compressing a tool through a sheet of raw metal with a punch press. Punching is generally faster and less expensive than laser cutting.

Laser cutters cut sheet metal by focusing light energy into a laser beam and supplementing it with cutting gas. The sheet stays fixed as the laser head moves in the ‘X’, ‘Y’ and ‘Z’ axes, unlike punches. Part numbers and labels can also be etched with lasers. Laser cutters are more precise and give a more finished edge.

Material Graining

Graining is the method of giving sheet metal pieces a consistent surface finish. This is accomplished by grinding the metal with a belt grinder.

Drilling – Countersinking – Tapping

Drilling produces higher-quality holes that can be used in materials of greater thickness. After that, thread-tapping and countersinking are often done. Thread tapping produces threads inside the drilled hole so that a bolted link can be made later. Countersinking a drilled hole eliminates the sharp edge, provides a bevel, and a recess (deep bevel) for a blind bolt head.

Forming – Bending

Cold working activities such as metal bending and shaping allow the sheet metal to be shaped to configurations that allow for creation of the optimal parts.

Hardware Insertion

Hardware insertion gives sheet metal parts more depth for load bearing threads. Hardware insertion makes use of existing holes created by high-precision machines like a laser cutter or a waterjet cutter, which improves the accuracy of the fastener’s placement.

Mechanical Assembly

Describes the process or final product of putting together sheet metal project components on an assembly line.

TIG, MIG, Spot Welding & Weld Grinding

Welding is used in creating more than half of all of the products manufactured in the United States. MIG welding is the fastest option, but the results are not as smooth as TIG welding.

The spot welding process is used primarily for welding two or more metal sheets together by applying pressure and heat from an electric current to the weld area.

Weld grinding is an important step in many metal fabrication processes, and it involves extracting excess weld metal in a clean and efficient manner.

Welded Assemblies & Frames

Sheet metal can be used to create complete welded assemblies and frames for large projects.

Bends

Bending is used to deform a material to an angular shape through the application of force. It is one of the most common sheet metal design methods and may also be called press braking, flanging, die bending, folding or edging.

Wall Thickness

The thickness of the sheet metal will affect how it should be handled and the force needed to apply design methods.

Bend Relief

An incision cut along the sides of a proposed bend in sheet metal to prevent tearing and part deformation during the bending process. Bend relief lengths and widths vary between projects and depending on the metal used.

Slots and Holes

Holes and slots must be at least as wide in diameter as the material is thick. It’s also important to consider distance from the edge. If a material is 0.036 in. (0.914mm) or thinner, the hole should be 0.062 in. (1.574mm) from the material edge; if the material is thicker than 0.036 in. (0.914mm), the hole should be at least 0.125 in. (3.175mm) from the material edge to avoid distortion. Hardware inserts may affect these requirements.

Tabs and Notches

Tabs and notches also come with distinct requirements for effective metal fabrication. Notches must be at least the thickness of the material or 0.04 in. (1.016mm), whichever is greater, and no more than 5 times the width of the material. Tabs must be at least 2 times the thickness of the material or 0.126 in. (3.200mm), whichever is greater, and no more than 5 times the width.

Hems

Hemming is a metalworking technique that involves rolling the edge of sheet metal over and onto itself, forming a two-layer field. There are two types of hems, open and closed. The tolerance of a hem is dependent upon the hem’s radius, material thickness and features near the hem. Ideally, the minimum inside diameter should equal the material thickness, and a hem return length of 6x material thickness.

Countersinks

Conical holes are cut into a manufactured item to allow a screw, nail or bolt to be inserted flush with the surface.

Offsets

Offsets are used to create Z-shaped profiles in sheet metal parts.

Welding

Welding fuses metal parts together by melting them together with high heat and then allowing them to cool. There are multiple types of welding, and the ideal strategy will depend on your material and project.