Sheet Metal

Why Choose Us?

Engineering & Quality Control
Our robust engineering department, advanced quality management systems, team of highly trained professionals, and more than 13 years of machining experience ensure your job will get done right. Our quality-minded professionals are trained in all aspects of quality and written procedures, in order to assure that all our customer's specifications and requirements are met every step of the way.

Wide Product Range
We provide rapid prototyping and low volume production orders to customers in a variety of industries: Aerospace, automotive, defense, industrial machinery, agricultural machinery, construction machinery, transportation equipment, medical equipment accessories, and more.

Reliable On-Time Delivery
We use sophisticated job scheduling software and job tracking systems to monitor the progress of every job in production on a daily basis. These key factors have allowed us to provide our customers with consistently reliable on-time delivery.

Superior Customer Communications
We keep our customers well informed throughout every stage of the production process, from initial quoting through final delivery. Quotes are submitted in a timely manner, orders are promptly acknowledged, and manufacturing processes are monitored on a daily basis to ensure on-time delivery.

What is Sheet Metal?

Sheet metal is a very thin and flat metal piece that has been formed into a specific shape or size. It is typically made from materials such as aluminum, steel, copper, or brass and is commonly used in a variety of applications including industrial and commercial construction, automotive manufacturing, and appliance fabrication. Sheet metal can be molded into various shapes and sizes, such as forming curved surfaces or angles, and can be manipulated by cutting, welding, folding, and other manufacturing processes.

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Advantages of Sheet Metal

1. Strength and Durability

Sheet metal is strong and durable, and sheet metal parts are often able to withstand greater pressure and heat than those made with plastic. In addition to this, aluminum, stainless steel, or surface-treated steel are all resistant to pressure, corrosion, and wear and tear. While a method like casting will share these benefits, plastic will not hold up as well with the passage of time.

2. Malleability

In addition to being durable, sheet metal is also malleable. With the right equipment, it can be bent into numerous shapes, while still retaining its strength and structural integrity. Sheet metal also has the ability to be compressed or stretched without breaking or cracking. When a part is cast or molded, you get a very specific shape, and usually expensive, mold. If you decide to change your part at all, it can be very expensive to invest in a new mold, and tooling for plastic can be very expensive as well. With sheet metal, it's as simple as bending the part in a different place to create a new and unique shape. The malleability of sheet metal allows it to be effectively and efficiently used in custom, complex, or highly specialized applications.

3.Replaceability

One of the biggest advantages of using sheet metal is that the parts are replaceable. If several metal parts are used to make an assembly, instead of making the whole part out of one substance, the individual components can be removed and replaced without having to replace the entire assembly. This can save money on repairs and even allow for modifications and upgrades.

4. Sustainability

As far as materials go, metal is by far one of the most sustainable materials. Metal is a natural resource that is both environmentally and economically strategic. When the parts are no longer needed, they can be recycled indefinitely and turned into other parts. Plastic has a limited ability to be recycled and cannot be easily and safely disposed once it reaches its end point. Metal manufacturing is a much more responsible and sustainable option.

5. Cost-Effectiveness

Tooling costs for plastics can be very expensive, making sheet metal a more economical choice. Many companies move from cast or molded parts to sheet metal because of the overall reduction in costs and material waste. Material lifespan and longevity must also be considered when evaluating the cost of material. The cheapest material is not necessarily the most cost-efficient option if it will not serve you well for a long period of time and has to be consistently replaced or maintained. The strength and durability features of sheet metal make it a more cost-effective option.

Types of Sheet Metal

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Alloy Steel
As the name suggests, alloy steel combines multiple elements to enable a customizable set of properties. The main component of this material is carbon steel. Common additions include tungsten, chromium, and manganese, for rigidity, or vanadium and nickel, for strength. In addition to its versatility, alloy steel is also highly affordable.

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Stainless Steel
This type of sheet metal is ideal for products that will be exposed to frequent moisture. It contains chromium, an element that significantly reduces corrosion caused by harsh or damp environments. Components made from stainless steel sheet metal fabrication can increase the lifespan of a product or structure, from kitchen sinks to office buildings.

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Carbon Steel
Iron is alloyed with carbon in this sheet metal material, providing an option with high amounts of strength. Depending on the desired application, a manufacturer can choose from steel with low, medium, or high levels of carbon content.

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Tool Steel
Immensely versatile, tool steel is a rigid alloy containing about one percent carbon. As with alloy steel, the elements contained within tool steel vary in type and ratio depending on the desired application. Tool steel is resistant to abrasion, and functions well in extreme temperatures. Its properties make this type of sheet metal ideal for the construction of tools, such as punches, dies, blades, and hammers.

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Galvanized Steel
Galvanized steel is available in two varieties: electro-galvanized sheets and hot-dipped metallic-coated sheets. The former is composed of cold rolled annealed steel. It has a pure zinc coating with no zinc spangle. The latter is composed of cold rolled hard steel plates coated with a mixture of pure zinc and an iron-zinc alloy. This type of galvanized steel offers more corrosion resistance, and is slightly more affordable than electro-galvanized sheets.

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Aluminum
For applications that require a more lightweight material, aluminum is an excellent option. This type of sheet metal offers significant corrosion resistance even without a finish. Aluminum is also strong, and can undergo laser cutting, welding, and machining.

Application of Sheet Metal

Transportation Industry
The automotive industry uses sheet metal for almost all operations and products. This industry uses sheet metal for cars, trains, buses, and rail cars. Sheet metal is also common for components in these vehicles, like oil pans, hoods, roofing, seating, and springs. Various aspects of a car, including engines and hoods, consist of sheet metal.

Construction Use

The construction industry uses sheet metal the most. Given its versatility, construction workers use sheet metal for many projects, like balconies, frames, industrial walkways, staircases, and support beams. Manufacturers use sheet metal to hold structural components in one place and support the entire structure. They also combine sheet metal with other materials to create floors, ceilings, or walls.

Plumbing Systems

At the turn of the 21st century, sheet metal became popular for plumbing systems because of its versatility. Galvanized metal piping made of sheet metal will last longer than lead and iron pipes.

Arts and Decoration

Sheet metal has many recreational and artistic uses, and many artists and architects take advantage of that fact. For instance, playground equipment like swings, slides, and see-saws contain sheet metal. Artists can make sculptures, decorations, and other artistic pieces with sheet metal. Consumers are even using sheet metal in their homes! Many people like metal bookcases more than wood for their striking presence.

The History of Sheet Metal

The sheet metal fabrication process goes back thousands of years, and has changed a lot since then. Research shows that the use of sheet metal began somewhere between 5,000 and 4,000 BC. Back then, people used stone to shape metal. For example, sheets of metal were used to create armor so that men were safe at war. Today, we have machines and technology that make the process much easier. Multiple technologies were developed from sheet metal fabrication. Over time, the world saw many innovations like the press breaks, the assembly line, and eventually the hydraulic press.

What Is Sheet Metal Made Of?

During the sheet metal fabrication process, different types of metal are often combined into one sheet. Metals that are used include brass, copper, aluminum, tin, nickel, steel, and zinc. Precious metals like gold and silver are sometimes used in sheet metal as well, but these are less common because of cost.

How to Machine Sheet Metal?

Punching

In punching, the sheet metal is punched out with a manually or automatically operated press, punching machine or punching tool and thus separated. Punching is mainly used in the production of small components from flat metal strips.

Laser Cutting

In this method of cutting, the heat of a laser beam ensures that the sheet metal is divided. As a very flexible tool, the laser is particularly suitable for processing thin sheets. If fine kerfs and high quality are required, laser cutting is the most common method in flexible sheet metal processing.

Plasma Cutting

This process belongs to the methods of thermal cutting. A plasma volume flow is used here, the heat of which leads to local material liquefaction. The high kinetic energy of the plasma volume flow blows out the liquefied material. The process is usually used for sheet thicknesses between 10 and 50 millimeters.

Flame Cutting (Oxyacetylene Cutting)

In this cutting process, the sheet is heated locally to ignition temperature by a fuel gas-oxygen flame. The supply of oxygen creates a kerf at which the sheet is then cut. If metals with large material thicknesses are to be cut, flame cutting is the most common method.

Bending

Press braking or bending describes the forming of sheet metal. In this process, the sheet metal is placed on the die of a so-called press brake. A tool then moves down onto the workpiece from above and bends the desired angles into the component.

Round Rolling

Round rolling is also a frequently used forming process. In this process, the sheet is usually plastically deformed over three rolls in order to bend it round.

Roll Forming

This process is also one of the methods of forming. In this process, the sheet is unwound from a coil and passed through several pairs of rolls arranged in a row until it is bent into the desired shape. This process is generally used for elongated profiles in high volumes.

Deep Drawing

In deep drawing, the sheet metal is specifically pressed into the desired shape by a tool. As a rule, tools act on the sheet metal through automatic punching machines or forming presses. As the tooling costs often incur considerable one-off costs in production, the processes are often used for high volumes.

Common Problems of Sheet Metal Designs

Hole Sizes
Punching holes can lead to the distortion or breakage of the metal during manufacturing. In this case, one of the best sheet metal design tips is to punch holes whose diameter is the same or greater than the thickness of the sheet metal.

Bend Relief
Adding a bend line to sheet metal design is a simple way to ensure the implementation of a design during a sheet metal project. A bend relief is an indentation in a straight line that makes the bending process easier and more exact. Doing this can help prevent distortion or tearing in the final product. To produce a minimum bend radius, the depth of the bend relief should be at least equal to or greater than the interior radius of the bend. However, the width of the bend should not be equal to or greater than the sheet thickness being used.

Distance Between a Bend and a Hole

Another one of the best design strategies is to leave a good amount of clearance between a hole and bend. That way, you can prevent the hole from deforming when the sheet metal is bent during production. Aim for a distance between the bend line and edge hole of at least two times the sheet metal thickness.

Minimum Flange Widths

Ensure that your product design includes a flange width four times the thickness of your sheet metal sheets. If you do not practice this during your manufacturing process, the finished product will have marks on its surface.

Bending Radius

There is no singular bend radius. It will depend on the manufacturing process and the tool being used. More flexible metal (thin sheets) will yield a smaller bend radius.

Design Considerations in Sheet Metal Forming

Material Thickness
The thickness of the metal sheet impacts its formability and the complexity of shapes that can be achieved. Thinner sheets are more conducive to intricate bending and forming, while thicker sheets may require specialized processes to achieve desired shapes.

Bend Radius
The bend radius determines the minimum achievable curvature in a metal sheet, influencing the ease of forming and the structural integrity of the final part.

Tolerances
Tolerances in sheet metal forming refer to the permissible deviation from specified dimensions, and they play a critical role in ensuring the functionality and assembly of fabricated components. Incorporating these design considerations and understanding their impact on the forming process is essential for optimizing the production of intricate and high-quality sheet metal parts.

How to Cut Sheet Metal?

Gather Your Materials and Set Up Your Station

First, gather all the materials in the previous section to ensure they are ready to use when you need them for the upcoming steps. Next, you will want to set up your workstation. You need something to support the size and weight of the metal you want to cut. You may use a sheet of plywood or some sawhorses to DIY your perfect workbench.

Plan Out Your Cut With A Sketch

Next, you will need to plan where you want to cut. This is where your measuring tools and pencil come in. You will use them to sketch out the exact measurements you need to cut through your metal. You will want to clamp your metal during this step to keep it in place while you sketch.

Use Your Tin Snips

In this step, you will need to apply your safety materials and get ready to get to work. This is where you will take your tin snips and start cutting your materials. To do so, you will need to open the tin snips and use them like scissors. You then cut on your sketch line and cut down the handles, and keep going along your drawing to finish your cut.

If Needed, Cut a Hole in the Middle of Your Sheet Metal

This step only needs to be completed if you need a hole in the middle of your sheet. This is where your power drill comes in. You will need to sketch a hole in the middle of your sheet metal and then use a power drill to drill a hole. This is so you can get your snips in there to make the bigger circle that you sketched.

File Your Metal

Finally, you would need to complete all the cutting from the previous steps. Then you will take a metal file up and down the edges. This is so you can clean it up and remove any burrs from your cut. Keep doing so until you have smooth edges.

Quality Control in Sheet Metal Forming

Significance of Quality Control Measures in Sheet Metal Forming

Quality control is paramount in sheet metal forming to guarantee the reliability, safety, and performance of fabricated parts. Implementing robust quality control measures throughout the forming process is essential for detecting defects, ensuring dimensional accuracy, and upholding material integrity.

Inspection Techniques and Testing Procedures in Precision Fabrication

An array of inspection techniques, including coordinate measuring machines (CMM), optical profilometry, and non-destructive testing, are employed to assess the dimensional accuracy and material properties of sheet metal components. These rigorous testing procedures are crucial for validating the quality and reliability of formed parts.

What Is the Difference Between Plate and Sheet Metal?

The main difference between them is the gauge (thickness) of the metal. Generally speaking, a sheet is a thinner item of metal that has been cut from a continuously rolled coil. As such, it can be less than 1mm, or up to 25mm, in thickness. A plate is a thicker item of metal that has been produced (rolled) as a single item. Thickness can be up to 150mm or more, but also as low as 2mm from certain producers. Therefore, it’s quite possible that certain thickness items could be produced via either process and described differently, although both are in the hot rolled condition. Steel plate is typically used in machines, structural sections and larger fabrications, whereas sheet is used in producing appliances and enclosures. They both have very different uses, depending on the varying durability and weight requirements for different projects.

Safety Tips for Dealing with Sheet Metals

1.Make Use of the Correct Tools
Without the correct equipment, handling any metal can result in damage. Metals are excellent conductors of electricity and heat, and untreated edges can be quite sharp. It can burn and slash the flesh if held in unprotected hands. As a result, all metalworkers should wear personal protective equipment (also known as PPE) to protect themselves from these potential hazards.
2. Examine Your Instruments
Take the time to test and inspect each of your power tools and machines before using them. It is recommended that all sheet metal processing tools be inspected on a regular basis to ensure that they are in good working order. This allows personnel to detect malfunctioning instruments before anyone is injured. Metal fabrication and production machines require a lot of maintenance since they are put under a lot of stress every time they are utilized.
3. Make Use of Proper Lifting Techniques
When working with sheet metal, lifting and transporting heavy items is a typical occurrence. Improper lifting practices, on the other hand, can result in a variety of back and neck ailments. Knowing how to lift these materials the appropriate way goes a long way when transporting them.
4. After each handling, clean up the area.
The presence of metal particles is a lesser-known hazard of dealing with sheet metal. Inhalation, ingestion, and, in some situations, skin penetration are all ways for metal particles to enter the body. Workers may unwittingly transfer these particles into their homes, exposing their friends and family.
5. Organize Yourself
While following safety measures will significantly reduce the risk of sheet metal accidents, these procedures will be rendered ineffective if the work environment is cluttered and unorganized. It's critical to keep the workplace clean and tidy in order to keep everyone safe. Clutter removal offers more advantages than simply keeping the place clean and ordered.

How Is Sheet Metal Being Used?

Sheet metal can be cut, stamped, formed, punched, sheared, bent, welded, rolled, riveted, drilled, tapped, machined. Hardware can then be inserted to fix electronic components, metal brackets or other pieces of sheet metal. To finish sheet metal, it can be brushed, plated, anodized, powder-coated, liquid painted, silkscreen, laser-etched, and pad printed. And of course, parts can be welded riveted into complex assemblies.
Just like any other technology, the processing of precision sheet metal is constantly evolving. Materials, processes, tooling, and equipment are becoming highly specialized which is improving the time involved to make common sheet metal parts and speeding up the design process as well. To fully leverage all the technological advantages, it is important that you select the right supplier and know the differentiation between metal fabricators; architectural sheet metal (HVAC and ductwork), heavy plate fabricators (staircases, fences, heavy structures) precision fabricators (thin gauge sheet metal, enclosures, brackets etc…).

Factors that Affect Sheet Metal Fabrication Costs

Raw Material Cost

The choice of raw material significantly impacts fabrication costs. Material type, thickness, grade, and finish all contribute to the overall expenses. Factors like material availability and pricing can help in selecting cost-effective options.

Labor Costs

Labor cost plays a pivotal role in sheet metal fabrication. Skilled labor, wages, and labor-intensive operations are key factors that influence overall expenses. Optimizing labor utilization and efficiency is essential for cost control.

Production Cost

Production costs play a crucial role in determining the overall expenses of sheet metal fabrication. These costs encompass various factors that directly impact the efficiency and effectiveness of the manufacturing process. When estimating fabrication costs, it is essential to consider set-up time, cycle time, scrap rate, and overall production efficiency.

Machine Usage and Tooling

The utilization of machinery and associated tooling costs contribute to fabrication expenses. Proper machine utilization, efficient tooling, and maintenance practices help optimize costs and enhance productivity.

Overhead Expenses

Overhead expenses encompass various costs associated with sheet metal fabrication, such as facility costs, utilities, equipment maintenance, and quality control measures. Managing these overhead expenses is crucial for budget control.

Outsourcing and Subcontracting

Outsourcing or subcontracting specific fabrication processes can impact overall costs. Manufacturers must carefully evaluate these approaches' benefits and considerations to optimize expenses without compromising quality.

Finishing of metal sheets

Brushing is used to deburr and remove surface defects from sheet metal parts. The surface pattern created is a uniform parallel grain resulting from the brush moving against the metal surface in one direction.

Plating is a process of coating a layer of metal to an object of different types of metal. This process is done, commonly, for aesthetic purposes or more practical reasons such as corrosion resistance and protection from wear and tear.

Polishing sheet metal as a means of finishing is where a layer of oxidation and also a thin layer of the material itself is ground off. In doing so it smooths out the metal, removing imperfections, and making it gleam once more. Generally, start with a coarse grit of sandpaper, like a 40 to 80 grit and then work towards a finer grit to finish off the polish effect.

Powder Coating creates a hard finish that is tougher than conventional paint. Powder coating comes in any color and therefore makes a great custom finish method when both durability and aesthetics are desirable finishes.

Abrasive Sand Blasting, more commonly known as sandblasting or media blasting, is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface or remove surface contaminants.

Our Factory

The company was founded in 2010. The company started from a small workshop with 5 CNC machines. After experiencing a difficult startup period, the business grows rapidly. Three years later, we moved to a larger plant and added 10 milling machines and 1 lathes. In 2015, Kevin decided to enter foreign market. With the rapid expansion of international business, the company moved again to a new location with 1500m2.

Ultimate FAQ Guide to Sheet Metal

Q: What is in sheet metal?

A: There are many different metals that can be made into sheet metal, such as aluminium, brass, copper, steel, tin, nickel and titanium. For decorative uses, some important sheet metals include silver, gold, and platinum (platinum sheet metal is also utilized as a catalyst).

Q: What is the cheapest type of sheet metal?

A: Hot Rolled Steel Sheets are the most economical steel sheets available for a wide variety of applications and projects. Having a slighty grainy surface, its ideal for painting.

Q: Is sheet metal the same as steel?

A: Steel plate metal can be defined as a sheet of metal 6mm or thicker. Steel plate is measured in inches whereas sheet metal is measured in gauges. Steel plate can be segmented into low, medium, and high carbon steel plates. Higher carbon content increases the strength and hardness.

Q: Why is sheet metal so expensive?

A: With the economy rebounding and the demand for new construction picking up rapidly, steel mills across the country are struggling to keep up. If you know one thing about economics, it should be that when demand is high and supply is low, prices are going to skyrocket—and that's exactly what is happening.

Q: What sheet metal is strongest?

A: Tungsten. Tungsten has the highest tensile strength of any pure metal – up to 500,000 psi at room temperature. It has the highest tensile strength even at temperatures over 1,500°C. Tungsten is so dense that it resists melting, even under extremely high heat.

Q: What is the strongest type of sheet metal?

A: High carbon steel is an alloy that contains between 0.60%-2.5% carbon. Due to the increased carbon content, the material has increased hardness compared to stainless steel. Consequently, it is more durable than either aluminum or stainless steel. It is very unlikely to warp, deform, or scratch under heat or force.

Q: What type of sheet metal should I use?

A: Mild steel is by far the most commonly used material for sheet metal fabrication. The relative strength it has, combined with the ease of fabrication and relatively low cost compared to stainless steel or aluminum, means that it's suitable in plenty of applications.

Q: What thickness does sheet metal come in?

A: Charts for aluminum, steel, stainless steel, and galvanized steel sheet are presented here, with thicknesses ranging from 1/64 to 1/4 inch. Gauge numbers continue both to thicker and thinner sections, but these charts cover the most common ranges.

Q: Does sheet steel rust?

A: Galvanized steel is coated with a layer of zinc to protect it from rusting, but over time, rust may still develop on the surface of galvanized steel sheets, especially if the coating has been damaged or compromised.

Q: Can you paint sheet metal?

A: You can easily paint metal if you have the right paint and do a little bit of prep. Doing it right the first time means the paint sticks better, you won't need multiple layers, and you'll have a better finish for longer.

Q: What is sheet metal mainly used for?

A: Sheet metal is one of the most versatile and widely used construction materials, with applications in just about every industry imaginable from mining, construction, farming, catering, hospitality, shipping, manufacturing, aviation, medical and transport.

Q: How tough is sheet metal?

A: Sheet metal is as strong as regular metal that thick. However, it needs to be have its reinforcements. Flanges, support coming in from the back side, an extra layer, all that good stuff. This is because it's a lot less resistant to bending when hit from the side without those.

Q: Is sheet metal cheaper than wood?

A: Metal tends to be cheaper than wood, with an average of $19-$25 per sq ft for a steel building and $20-$35 per sq ft for a wood building. Also, using metal in your build has a lower lifetime cost due to near-zero maintenance, and it can be nearly 100% salvaged and sold if it is ever torn down.

Q: What is the thickest gauge of sheet metal?

A: The standard sheet metal gauge range begins at 30 on the thin end and drops down to 7 at the thicker end of the scale. However, the actual thickness and corresponding gauge will differ depending on the type of metal. Many metals can be produced in gauges up to 36 or down to 3, which is way beyond the average range.

Q: What sheet metal doesn't rust?

A: To prevent oxidation and breakdown of metal products, such as handrails, tanks, appliances, roofing, or siding, you can choose metals that are “rust-proof” or, more accurately, “corrosion-proof.” Four basic types of metals fall into this category: Stainless steel. Aluminum metal. Copper, bronze, or brass.

Q: How do you make sheet metal more rigid?

A: Creating ribs or groove designs into the sheet metal increases strength significantly while adding to the design of the panel. This is because the stretched metal on those areas hold tension better and improves its structural rigidity.

Q: What is the thinnest sheet metal?

A: The thickness of any metal mainly depends on its application. The thickest sheet metal out to have a 6mm thickness, with the thinnest having around 0.5mm. This article takes you through the process of sheet metal thinning, how it happens, and what determines the thickness of sheet metal.

Q: Can you cut sheet metal at home?

A: Roofing, sheet metal, and corrugated metal—basically any metal that generally requires just a simple, straight cut—can be cut by a circular saw with the right blade. And, depending on the blade you choose, you may be able to stack up a couple of pieces and cut them all at once, reducing your cutting time.

Q: Can sheet metal get wet?

A: Sheet metal that is exposed to water needs to be as resistant as possible to corrosion. Whether the metal sheeting is used for roofing, machinery, or any other purpose, it's critically important that it's able to withstand wet conditions.

Q: Why do we bend sheet metal?

A: Sheet metal bending is an operation that involves using forces to change the shape of a sheet. This is done to achieve the desired form or shape needed for a manufacturing process. The external force used alters only the external features of the sheet.

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