Everything You Need to Know About Custom Sheet Metal Fabrication

by Staff

Custom sheet metal fabrication is a specialised niche of the manufacturing sector. Sheet metal, usually steel or aluminium, is cut and formed into useful shapes for a wide array of applications including automotive parts and hinged doors. It’s not just industrial products that can be custom fabricated, either. In this article, we will discuss all that you need to know about sheet metal fabrication.

The sheet metal fabrication process

There are three main processes involved. They include;


This refers to the process of reshaping sheet metal. What happens is that metal is pressed into shape. In some cases, the metal may be stretched to make it longer. Bending is also done to smooth out any rough edges. What follows is that the metal is then taken through a pair of rollers to eliminate any wrinkles or bumps. This results in the coiled shapes that make up a metal part.


After the metal has been formed, it is then cut using a variety of cutting tools like lasers or plasma cutters. In some cases, the metal may be punched to create holes that are needed for certain purposes. It is important to note that there are two categories of cutting when it comes to metal fabrication. They include;

Shear cutting. This is a less precise cutting technique that involves the use of liquids, gases, or solids to cut the metal. It is ideal for smaller-scale custom fabrication projects that don’t require a lot of precision.

Non-shear cutting.

According to Eko Industries (https://www.ekoindustries.com/sheet-metal-fabrication), this includes laser cutting, waterjet cutting, plasma, and flame cutting. It is more precise than shear cutting and it allows for complex shapes to be created. The downside, however, is that it is only ideal for large-scale projects with a lot of detail incorporated into the work. The accuracy in these processes is due to the computer-aided design that is used.


This is the process of welding the metal parts together to form a larger piece. There are several ways that this can be done. The most common of which is the resistance welding process which uses a special type of welding wire that is heated and then forced into place. A filler material is also added to make sure that the welded parts are uniform and free from blemishes. The result is a very strong weld. Depending on the process used, resistance welding can last for years.

Tools and equipment used in the sheet metal fabrication process

There are several tools and equipment used specifically in the sheet metal fabrication process. They include;

-Cutting tools. These are used to cut the metal and make different shapes out of it. There are various types of cutting tools but the most common that can be found in any shop is the plasma cutter which uses high-temperature gases to produce a very hot flame that cuts through metal like butter. They include mitres, saws, Band saws, laser cutters, shear cutters, and others.

-Forming process tools. The tools involved here include Rolling Machines, Shears, CNC machines, and others. These machines are used to form the metal into its desired shape.

-Joining process tools. The tools involved in this process include Rivet Guns, Flux, Welding equipment, and many more.

-Hand tools. These are used in the general process of shaping, forming, and cutting metal. They include hammers, wrenches, screwdrivers, and other manual tools for making adjustments to the product if necessary.


As you can see, there are a lot of tools and processes involved in sheet metal fabrication. If you are planning on starting or working in this industry, you will need to have a thorough understanding of them.

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The New Jersey Digest is a new jersey magazine that has chronicled daily life in the Garden State for over 10 years.

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