What is a metal fabrication company?

Metal fabrication is a manufacturing process used to shape metal into parts or end products. Most people think of welding when they hear metal fabrication, but welding is just one process metal fabricators use. We use several techniques to shape sheet metal into a part or good.

Though fabricated metal products are common and metal fabrication is a critical part of the manufacturing process, few people understand how the process works. From paper clips to plane parts, it’s used to create a wide variety of products for almost every industry. The United States saw nearly $353 billion USD of fabricated metal production in 2020 alone!

Most metal fabrication uses sheet metal, which can be up to 0.25 inches thick. Fabricators convert this sheet metal into products or tools that get stamped, folded, shaped or joined to create a finished component.

Some examples of products made from fabricated metal include:

• Hand tools
• Bolts, nuts and screws
• Cans
• Cutlery
• Pipes and pipe fittings
• Metal windows and doors
• Equipment attachments
• Car parts

Metal fabrication is important in making parts for mass consumption. Products like cans, screws, cutlery, pans and pipes are included in this category. These products tend to have consistent requirements and a wider tolerance for error. This means that the parts can differ in small ways from the original design and still function as expected.

Metal fabrication can also create large runs of customized fabricated metal products. These projects usually include the design and fabrication of customized metal parts to fit a business’s needs. Customized valves, car parts and hardware are all examples of this type of project.

The Metal Fabrication Process

Although most metal fabrication focuses on the shaping and cutting of metal, there are multiple steps involved in a successful fabricated project. The process starts with a design or rendering and ends with a finished, functional part.

Designing a Metal Fabrication Project

The first step in any project is design. Some businesses come to us with a completed design. More commonly, businesses come to us with a prototype. We work with them to refine and test the design before starting a large run.

Today, many metal fabricators use Computer Aided Design (CAD) or Computer Aided Manufacturing (CAM) during the manufacturing process. With CAD and CAM programs, we’re able to develop a 3D prototype of an object before we actually begin to manufacture metal products.

Because a project can include many components, this phase helps ensure the product will function as required. From the prototype or rending, we’ll determine the size and shape of each part required and clarify the types of metal and finishing techniques needed.

Fabricating the Part

The actual building process is the second step of a metal fabrication job. During this phase, we cut and shape each of the components from the design phase. The tools used to fabricate metal can include shears, mills, lathes and nibblers.

We often use CNC tools, or Computerized Numerical Controls, to ensure each piece is cut exactly to the specifications of the design. These tools extract a computer program of the exact commands and specifications used to create a piece. This program is then loaded into the CNC machine.

The finishing and assembling processes then strengthen the product and ensure it’s ready for use. Finishing techniques like grinding and deburring ensure the materials function properly and have no excess material. Metals might also be heat treated or plated with zinc or similar finishes for additional strength.

Fabricators also make sure products are marked and printed according to each project’s specifications. This can include measurements, company logos and other information.

Industries That Use Metal Fabrication

Metal fabrication has applications in a wide variety of industries. Because of the versatility of tools and processes, it’s used to create parts for industries as varied as agriculture, spas, military craft and cars.

Some industry applications for metal fabrication include:

• Commercial and military aircraft parts.
• Agricultural equipment and attachments.
• Alternative energy components for solar, wind and geothermal structures.
• Individual parts for automotive and recreational vehicles.
• Materials, tools and supports for construction projects.
• Food-safe food processing and packaging equipment.
• Consumer product creation for everything from home appliances to car seats.
• Military defense tools, communication equipment and vehicle components.
• Fracking tanks and pumps.

What Does Metal Fabrication Look Like in Different Industries?

Fabrication is often associated with the automotive and heavy equipment industries. It’s used to make a variety of car parts, from engine components to caps and valves. We also manufacture components for planes. But metal fabrication doesn’t always mean small components. We also cut and join large pieces for tanks and transport vehicles and manufacture components for heavy-duty equipment.

Some industries have niche-specific requirements, like metal fabricated spa furniture or custom parts for lighting or machinery.

Metal Fabrication Techniques

The metal fabrication process goes beyond simply shaping metal, and even the most straightforward products may require a variety of techniques and processing steps. Most metal fabrication falls into three primary categories:

• Commercial: Commercial fabrication refers to work done while creating commercial products. This category covers goods designed for use by consumers. Appliances and cars are both common consumer products that use commercial fabrication.
• Industrial: Industrial fabrication creates pieces for other equipment, which is used to manufacture consumer goods. Many manufacturers use products created through industrial fabrication, such as ironworking machines and bandsaws.
• Structural: Structural fabrication refers to metalworking done as part of the building process. These are typically large-scale fabrication projects that create the metal components for shops, manufacturers, buildings and skyscrapers.

Within these categories, a fabrication project might entail one or several of the following processes:

• Laser cutting: A technique that uses high-intensity light beams to cut metal via burning, melting or vaporizing.
• Centerless grinding and polishing: A finishing technique for tightly toleranced metal products that creates a smooth, consistent finish.
• CNC machining: A method of fabrication for prototyping and high-volume production that utilizes programmable computer software for ultimate precision and efficiency.
• Bending and forming: The use of hydraulic equipment, CAD/CAM capabilities and various tools to bend and shape materials to fit specifications.
• Powder coating: An alternative finishing method to paint that creates a custom, durable coating for metal parts.
• Saw cutting: A highly precise cutting method requiring skilled workers and specialized saw blades.

Metal Fabrication and Processes

Every industry has different needs, and each fabricated piece has its own specifications. The metal fabrication process might include a variety of methods to reduce, shape and join materials.

Reduction Processes

Some of the most common metal fabrication processes are reduction techniques. These processes remove parts of the metal to create a correctly sized and shaped piece.

Examples include:

• Shearing: Shearing reduces metal pieces to the correct size or shape is common for aluminum, steel, stainless steel, brass or bronze. Shearing is most suitable for flat sheet metal. In shearing, a stationary blade holds the metal in place while a movable upper blade slices through the metal from above. Blades are mounted at an angle to produce diagonal cuts. Shearing only produces straight lines but can create a variety of shapes.
• Punching: Used to place holes in sheet or rolled metal, punching is most suitable for high volume production. Punching involves a hardened metal punch placed above the metal and a die beneath it. The punch produces a slug of metal within the hole, which is usually recycled. Punching helps remove excess material from the work surface.
• Blanking: Used to create metal workpieces for medium and high production workloads, blanking is best for sheet or strip metal and more suitable for softer metals like aluminum. During the blanking process, machines force a punch through the metal into a die. The piece that’s cut out during blanking is the new work surface. The material produced by blanking is usually larger than that produced by punching and usually undergoes other metal fabrication processes. Manufacturers usually punch blanks closely together to reduce waste.
• Notching: Used to create detailed cuts and angles that aren’t possible with standard shearing processes, notching can be used on a wide variety of metals. However, it is most suitable for sheet or rolled metals. It’s usually lower volume than shearing. Nibbling is another industry term for notching. Notching removes materials from the outside of a piece of metal. One or more blades placed at angles remove excess material from the metal. Notched materials often go through multiple rounds of notching to arrive at the final shape.

Shaping Processes

Sometimes metal needs to be shaped instead of simply cut. There are varieties of different processes used to shape metal. During the fabrication process, metal is usually cut first, then shaped.

Shaping examples include:

• Stamping: Stamping creates one or more raised sections of metal. Often used when fabricating medium to large batches of parts, stamping might refer to progressive die drawing, shallow stamping or deep stamping. In stamping, metal placed between a stamp and a die creates a raised or lowered surface. Many stamping processes are relatively shallow and create a narrow surface. This is why it’s most suitable for sheet or rolled metal. Used in sequence, multiple stamps or dies help create the final piece.
• Folding: Folding creates angles in sheet metal during the fabrication process.

Other Processes

Several other processes used during the metal fabrication process join different sheets of material together or shape large blocks of metal, such as:

• Welding: Welding is one of the most common ways to join pieces of metal. A skilled welder can extend sheet metal and join it with a number of unique joints. There are several types of welding, including robotic welding, TIG and MIG welding. TIG welding, or Tungsten Inert Gas welding, is usually used when handling very thin materials or when it’s important not to deform the metal. MIG welding, or Metal Inert Gas Welding, welds joints in thicker metals.
• Machining: Machining, sometimes considered a separate industry from metal fabrication, actually plays a vital role in the process. However, many metal fabricators also do machining. Machining shapes blocks of metal instead of sheets or rolled metal. Machining removes pieces of metal from the block to shape the final product. There are a number of tools used in machining. Lathes, mills and drills are some of the most common.

How to Choose a Metal Fabrication Partner

Finding the right metal fabrication shop for your project can be challenging. Asking a few questions ahead of time can help you find the right fabricator. Here are five questions you should ask a metal fabrication shop before you decide:

1. Does the Company Have the Capacity for Your Project?

When choosing a metal fabricator, one of the first questions to answer is whether the company has the capacity to take on your project. There’s a wide variety of metal fabricators in business. Some specialize in working with just one industry. Others offer a range of services.

If your fabrication project is complicated or has a very narrow tolerance for error, look for a company that specializes in precision fabrication. If a metal fabricator serves this field, they’re likely to have the skills and experience needed for other precision work.

Ask what the company’s standard project size is, as well. If a fabricator specializes in individualized products, it may not have the capacity to handle larger orders quickly.

2. What Services Does the Fabricator Handle In-House?

It’s frustrating to hire a fabricator only to realize some of their services are outsourced. The unfortunate reality is that many fabricators do outsource steps of the design or finishing process.

Before selecting a metal fabricator, ask which services they offer and whether they outsource any of them. Does staff handle all of the building and fabricating steps? What is their experience in the field?

It can also be helpful to ask about support during the design process. Can you work with engineers at the company to modify your design if necessary?

Some customers come to us with a complete computer rendering and prototype. Others want to test and modify designs before manufacturing a large run. Our in-house engineering team can work with these customers to modify designs and offer suggestions on how to obtain the higher-quality part.

3. How Many Staff Members Does the Company Have, and What Is Their Experience?

Experienced staff is critical for a successful metal fabrication project. Ask potential partners about the size of their staff and what experience they have in the field.

We recommend looking for businesses that have certified engineers and welders on staff. Certification provides proof that staff has the experience and skill necessary to complete your project successfully.

4. What Does the Project Bid Include?

It’s common to get several bids when shopping for a metal fabricator, but not all bids provide the same information. When comparing bids from fabricators, make sure you understand exactly what’s included in the proposal.

Some of the things to look for in a bid include:

• The services the business will perform.
• Whether modifications are included in the proposal.
• An estimate of how long the project will take.
• The cost of materials.
• Who is responsible for sourcing materials.

It can also be helpful to ask the business whether they’ve padded their bid and, if so, by how much. Most project proposals include some padding to account for any problems that might come up during the project, from modifying part of the design to sourcing materials.

5. Can the Company Source Materials and Complete Jobs on Time?

Some of the best fabrication businesses, like Summit Steel, call the USA home. If you’ll be fabricating parts for use in the States, finding a fabricator based in the US can make a big difference. It will reduce shipping time and costs and cut down on problems with sourcing materials.

You may want to find out whether the fabricator has a warehouse or factory near your company, particularly if you’ll be fabricating large or heavy parts.

The location of suppliers and a company’s relationship with them are also important. If a shop has a good relationship with its suppliers and pays its bills on time, they’re more likely to be able to source materials easily. This is particularly important if your parts will require less common metals.

The Future of Metal Fabrication

The metal fabrication industry will continue changing and growing as technology and increased market demand promise more streamlined fabrication processes. While much of this advancement will come from adopting more sophisticated technologies and better work processes, some of it also comes from increasing interest in applications like custom automotive fabrication.

Some trends to watch for include:

• Fabrication automation: Automated equipment, tools and processes mean fabricators can take on more projects in less time with fewer inconsistencies. For the consumer, this could look like lower costs per order and faster turnaround times for high- and low-volume orders.
• Innovation to compete with 3-D design: Additive design processes, like the rise of 3-D printing, will require the metal fabrication industry to stay competitive through new technologies and processes that match 3-D prototyping quality, speed and versatility. Though some applications will undoubtedly be better suited for additive creation, metal fabrication will remain a cost-efficient alternative for most industries.
• Advanced specification capabilities: A new generation of skilled fabricators with advanced CNC experience will push the metal fabrication industry forward with advanced software that makes it easier than ever to create ultra-detailed component designs and highly precise fabrication techniques.

Every time you get in a car, pick up the phone, handle a tool or turn on an electronic appliance, you are looking at the result of custom metal fabrication.

Our economy relies on metal fabrication processes. Without it, we wouldn’t be able to run our electrical systems or create the parts that keep our houses, kitchens, businesses, computers and vehicles operational. Some fabricated metal product examples include bolts and screws, cutlery, pipe fittings, car parts and even hand tools. However, it is difficult for many of us to understand what precision metal fabrication entails, as well as all of the areas of our lives it affects.

This article will serve as a metal fabrication guide, explaining metal fabrication’s definition, history, process, technology, types and applications. By the end, you will have a more in-depth understanding of how crucial this process is to civilization and how many different parts of our lives it touches.

Metal Fabrication Definition

Before we dive into the details of what metal fabrication is all about, we have to answer the main question: what is metal manufacturing and fabrication?

Metal fabrication is the process of manufacturing sheet metal and other flat metals to make them conform to specific shapes. The process starts with sheet metal around a quarter of an inch thick or less. At this thickness, the metal is pliable enough to assume different shapes. Using this metal, fabricators alter the sheet to create a specific shape. This takes place through cutting, stamping, shaping, folding and welding. Another related practice is custom fabrication, meaning the creation of new custom parts using novel combinations of these processes.

All this work is completed by metal fabricators — highly skilled specialists who are trained to cut and manipulate metal with a surgeon’s precision to the desired shape. These fabricators often work out of large-scale manufacturing operations or specialized fabrication shops. The shops themselves vary widely, offering general fabrication services or specialized fabrication for medical and IT industries.

Metal fabrication may require additional parts to be added during the process, including but not limited to:

• Plate metal
• Expanded metal
• Formed metal
• Wire for welding
• Hardware
• Fittings
• Castings

Of course, the processes and parts used will vary depending on the job. Essentially, a fabrication shop or machine shop will start with a collection of assorted metals and transform them into the tightly built structures so common in our everyday lives.

The History of Metal Fabrication

Humans have been mining and machining metal for the past 10 millennia, as evidenced by a copper pendant archaeologists found in northern Iraq that dates back to about 9,000 BCE. Fabrication shops as we know them today began to exist around the Industrial Revolution, when sheet metal was in much higher demand than before. The invention of the hydraulic press, which allowed manufacturers to apply unprecedented pressures to pieces of metal, transformed the metal fabrication industry.

Metal fabrication on a broad scale was necessary to form systems of railroads, telegraph lines, weapons, tools, printing presses and other implements that have been so instrumental in our history. All of these advances relied on machine shops performing joints, cuts, bends and forming operations, just as is done today. The advent of compressed air has made riveting, another important part of fabrication, much easier and more efficient.

With the onset of the 20th century, metal fabrication has assumed an even larger role in our lives. We now perform machining on grand scales, ranging from small, family-run operations to large manufacturing plants employing thousands of people.

Technology Used for Metal Fabrication

While metal fabrication has existed in some form for millennia, the practices and technology have evolved significantly over time. Many of the basic processes have been around for centuries, but there are significant innovations that have revolutionized how we fabricate metal products in the modern world. Some of the most significant types of metal fabrication technology that are now at the forefront of the fabrication process include:

• CAD software: Computer-aided design (CAD) software plays a significant role in the design of metal fabrication projects. Engineers use CAD software to develop designs, which can then be used by a fabrication company in the fabrication process. This software system allows for the production of 3D models as well as quick updates and changes to the design. CAD software also facilitates easy translations to programming language for programming fabrication machinery. Computer-aided design has made parts much easier to fine-tune, and it allows engineers to figure out crucial information instantaneously, including information on spots that may be structurally weak.
• Automation: Automation has revolutionized the fabrication process in recent years. Fabrication machinery is increasingly being produced with programming capabilities, allowing the machinery to automatically complete projects to specifications with minimal human involvement. This allows for round-the-clock work, as well as improved reproducibility and precision. Automated tools are available for a wide range of processes, including cutting, welding, folding and various machining processes.
• Machinery: Machinery solutions are also improving over time. Laser technology is being used in cutting processes, which allows for faster cutting through thicker materials. Other technologies, including plasma cutting and waterjet cutting, are also increasingly available. These methods are valuable for a range of different project and material types.

These technologies are expected to expand in the coming years, especially as fabricators push for greater flexibility in their equipment.

Types of Metal Fabrication Processes

There are various processes involved in metal fabrication. The specific combination of metal or stainless steel fabrication processes will vary with the geometry of the part, the type of usage it will get and what it is made of. Here are examples of some choices for different types of fabrication processes:

• Cutting: Cutting is the most fundamental process in metal fabrication, and it can be accomplished through laser cutting, waterjet cutting, shearing, sawing or flame cutting. This is what turns the sheet metal into a piece of the required size and shape. Today, waterjet and laser cutting comprise the foremost technologies available.
• Casting: A die forms a mold, and the fabricator pours molten metal into it. This metal cools down and turns solid, and the part remains after removing the die.
• Forging: High-pressure machinery compresses raw metal, allowing a fabricator to bend and shape it.
• Punching: Turrets punch pre-designed patterns into the metal, either for decorative purposes or utility.
• Drawing: This process uses tensile force to pull liquid metal into a tapered die.
• Milling: A milling mechanism bores perforations into the metal, which, due to the nature of the machine, can be non-circular.
• Drilling: A drill cuts holes into the metal using a circular bit.
• Turning: The piece of metal goes onto a spinning platform, allowing a technician to cut it radially with a tool as it spins.
• Extrusion: A ram forces billets through a die. This extrusion process forms cylindrical parts, such as pipes or electrical wires.

You will often hear these metal fabrication terms used during the planning stages of the metal fabrication process, so it is essential to familiarize yourself with these common processes and some of the machinery involved.

How Different Metals Are Fabricated

Metal fabricated products are created from a broad range of metals and their alloys. While most fabrication processes start with sheet metal versions of these metals, certain types of metals may start in the form of pipes, tubes or bar stock.

Below are a few of the common types of metal used in metal fabrication:

• Aluminum
• Steel
• Copper
• Tin
• Gold
• Magnesium
• Iron
• Silver
• Nickel

Most metals are available in stock metal forms, which typically include sheet or plate metal, bars, rods, fittings or wires. Metals like steel and aluminum may also be available in pipe or tube form, depending on the needs of the project. Precious metals, such as gold and silver, tend to be available in smaller wire, sheet or bar forms due to their value.

Most metals can also undergo a majority of fabrication processes, though limitations exist depending on the softness, pliability and thickness of the metal. For example, the rigidity of steel will affect the types of processes and amount of power needed for steel fabrication, meaning the processes will look different than it would for fabricating a more pliable metal like aluminum. To learn more about the different process requirements for a certain metal, reach out to a specialist in metal fabrication services.

How Does Custom Metal Fabrication Work?

Metal fabrication starts with an idea, typically born out of necessity, that involves a piece of metal suited for some particular task. For example, a tech company may need a machined aluminum case for a new gadget. Once they have the idea, companies will design the part and send it out to several machine shops as part of a request for a quote. The machine shops analyze the schematic, calculate the cost of production and reply with both cost and lead time.

At this point, the company chooses the machine shop they wish to work with. The shop then puts the order in their queue and sets about ordering materials for the machining job. This may consist of sheet metal, metal bars, metal rods and more. As soon as the parts arrive and the job is in the queue, the team sets to work building the part itself.

The full process for custom metal fabrication is described step-by-step below:

1. Design: The design phase involves analyzing and adjusting the design for manufacturing. While this step is often completed solely by the customer for more standard parts, the fabrication service provider is often involved for custom projects. During this phase, the manufacturer’s design team works with the customer to determine project requirements, manufacturing approaches and areas of improvement and uses CAD software to produce designs.
2. Prototyping: Prototyping is a common next step, though it isn’t necessary for every project. In this phase, a rapid prototype is produced using either 3D printing or rapid sheet metal prototyping. The prototype is then analyzed for feasibility, and the customer and design team can identify any adjustments that need to be made to the design before moving on to the next stage of production.
3. Programming: As soon as the CAD design for the product is finalized, it is translated into programming for any computer-controlled machines that will be involved in the fabrication process. Programming is often required for automated cutting, punching and turning machines.
4. Fabrication: After programming is complete, the fabrication process begins. The time it takes to fabricate depends on the complexity of the part, the processes involved and the demand on the machine shop. The fabrication process itself may include various steps, including cutting, punching, folding, machining, welding and more.
5. Finishing: Once the fabrication process is complete, the fabrication service may finish the product. This often includes refining surfaces and edges or applying various coating options, such as powder coating.
6. Assembly: Some fabrication services also offer assembly, which may involve welding or electrical integrations.

Why You Should Outsource Metal Fabrication

While some companies may have the capability to handle metal fabrication in-house, most companies don’t have the in-house machinery and expertise to accomplish this. Fortunately, outsourcing metal fabrication to a third party is an available option and presents significant benefits to companies with metal fabrication needs. Some of the common benefits of metal fabrication outsourcing include:

• Expertise: Metal fabrication services are dedicated to their craft and focus on studying the latest trends, technologies and practices in the field. They also employ experts in fabrication who have extensive experience they can deliver to your project.
• Consulting: An outsourced metal fabrication service can act as your partner, helping your company by reviewing custom project designs for manufacturability. This expert can be an extra set of eyes to help identify innovative design modifications, and they can help reduce costs by identifying areas of improvement that can decrease manufacturing and material expenses.
• Resources: Metal fabrication services already have the tools on hand to achieve any project you need. They also invest in the latest technology, ensuring your project is benefitting from advanced tools and techniques.
• Quality: The expertise, consulting services and technologies available from outsourced metal fabrication services can help your company achieve maximum quality with every project.
• Cost: Outsourcing your custom metal fabrication projects means your company doesn’t need to invest in costly equipment or maintain an expert workforce. By outsourcing your metal fabrication, you can avoid these costs while also leveraging your fabrication partners’ expertise and capabilities to maximize quality while reducing expenses.

When choosing a metal fabrication service, look for experienced companies with good resources and experience working with your industry or related fields. If you’re looking to outsource your metal fabrication services, Laserfab is here to help.

Learn More About Laserfab’s Metal Fabrication Services

Our metal fabrication services prioritize three factors: price, quality and delivery. While many companies excel in one or two of these qualities, Laserfab understands true value is about treating all three equally.

It all starts with filling out our Request for Quote form. We take every step possible to ensure the lowest price with the highest quality. You’ll receive your quote quickly, allowing you to make the most of your time.

Our production involves state-of-the-art equipment in a high-grade, professional facility that employs some of the industry’s best engineers and technicians. As soon as we finish your product, we will deliver it to your doorstep when you need it.

Contact Laserfab today to discover why we are leading the industry in high-quality metal fabrication.