Several types of metal fabrication techniques can be used to create intricate components in a variety of shapes and sizes, from cutting and punching to forming, shearing, and welding. The specific method or methods used depends upon the desired outcome, budgetary constraints, and the desired material properties. This article will discuss the common types of metal fabrication and their benefits so you can choose the method that best suits your project.
Cutting
Cutting is usually one of the first of many steps in the metal fabrication process; for simpler projects, it may be the only step. There are many cutting techniques to choose from, with advanced options offering greater precision and repeatability. Laser cutting is especially accurate and efficient while minimizing material waste.
Machining
Used in the production of many metal products, machining removes material from a metal workpiece to create the desired shape. Machining techniques include:
- Turning
- Milling (vertical and horizontal)
- Grinding
CNC machining is an automated process that allows for high accuracy and duplicability, even with the most complex designs. It’s also safer and more cost-effective than manual machining. Due to its low risk for errors, CNC machining results in less material waste, faster turnaround times, and greater productivity.
Forming
Forming is another common type of metal fabrication used to create structural components from metal sheets. The process typically involves using a brake press machine to apply pressure to the metal workpiece and shape it into the desired form. Sheet metal forming is suitable for manufacturing components used in products such as air ducts and ventilation systems.
Rolling
Plate rolling is a versatile metal fabrication method. It involves passing metal material through a set of rotating rolls, gradually bending it into a conical or curved shape. This technique allows for greater control over the tolerances and dimensions of the rolled metal plate, ensuring precise, consistent results.
Punching
A punch press is used to create holes of specific sizes and shapes in metal material. The metal that is removed from the larger piece is called a blank. While punching and blanking involve similar steps, they have different end results:
- Punching. This uses a punch to create a cutout in a piece of metal; with this process, the larger piece with holes in it is the desired result.
- Blanking. This removes specific shapes from a larger sheet of metal; those specific shapes are the desired result.
Both methods are fast, economical, and straightforward. Manufacturers can use punch presses to create components for a wide range of applications, including construction and automotive.
Shearing
Shearing is used to quickly remove unwanted material, leaving behind a clean, smooth edge. This metal fabrication method is cost-effective and doesn’t produce wasteful metal chips. It can be used on a variety of materials, including:
- Aluminum
- Steel and stainless steel
- Copper
- Bronze
- Iron
Welding
Using heat and pressure, welding is an effective way to permanently join metal pieces of any size or shape. Different welding techniques can be used for specific types of projects, including:
- MIG. Also known as gas metal arc welding, MIG welding uses bare wire filler to fuse metal components. This welding method is best for thin metal parts.
- TIG. TIG welding, or gas tungsten arc welding, uses a torch to heat a consumable rod and join metal components. It can be used for aluminum, copper alloys, titanium, nickel alloys, and steel projects.
- Arc Welding. Also called stick welding, this process uses an electrode welding rod to join two components. It’s best for large or heavy metal components that require strong welds.
The specific welding process will depend on the materials used, the type of weld required, and the desired form.
Metal Fabrication Services From Cenflex, Inc.
With more than 30 years of experience, Cenflex has established itself as a one-stop shop for various types of metal fabrication. Our services include cutting, forming, CNC machining, welding, punching, and more. As we continue to grow, we’re committed to investing in new technologies and techniques to serve our clients and lead the metal fabrication industry.
Contact us to learn more about the different types of metal fabrication we offer. You can also request a quote to start on your next project.