How to Start Metalworking: A Step-by-Step Guide for New Enthusiasts

Metalworking allows you to turn your ideas into reality and express your creativity in making finished products. And that’s the reason it sparks interest and compels new enthusiasts to get started.

But most beginners struggle to start metalworking. One of the most common reasons is a lack of knowledge related to metalworking processes, tools, safety, and metals.

We are here with a beginner-friendly guide on how to start metalworking. We will teach the fundamentals of metalworking and everything you need to know to get started. Most importantly, we’ll share the step-by-step process of making a simple metalworking project, which could be your first creation.

What is Metalworking?

The metal objects you witness are made from raw metals, but they have to go through a series of processes to have that shape. And that’s what metalworking is. It’s nothing but the process of shaping and reshaping raw metals to get the desired size and shape.

It’s the art and science of turning raw metals into a final product. People who do metalworking turn their ideas into reality with the help of metalworking techniques, such as cutting, forming, and joining.

Metalworking isn’t something new. It’s been practiced since the Bronze Age. The only difference is the technology. At that time, simple techniques like hammering were used, and now, we have advanced and computer-driven methods.

From the aerospace industry to jewelry making, metalworking is everywhere. Anything that’s made from metal has come through metalworking.

Fundamental Metalworking Techniques and Processes

Whether you are a beginner or a professional, these are the core metalworking techniques and processes you should know about.

Cutting

Often, metalworking starts with cutting. You take the raw material and cut it into the desired sizes or manageable pieces.

Here are the methods you can use for cutting:

Shearing: It is a process of cutting metals with sharp blades. For beginners, the manual shear is the best, and it looks like big scissors. You can make straight cuts with it on metal sheets. And there are also heavy-duty manual shears and even power tools.

Sawing: This method uses a toothed blade to cut metal sheets, pipes, bars, etc. Manual saws are suitable for beginners, but there are also power saws for large projects.

Turning: It is a performance on a lathe. The metal pieces rotate at a high speed, while a sharp cutting tool moves in a linear direction. It reduces the size of the piece by shaving it.

Milling: A sharp rotary cutting tool is used for milling. It spins at a high speed and moves in different directions to remove the edges of the material as desired. The workpiece remains stationary during the process.

Drilling: A simple process that uses a drill bit to make holes in the workpiece. The rotating drill bit moves up and down, while the workpiece remains stationary.

Laser Cutting: This is an advanced process that uses a powerful and focused beam of laser. It increases the temperature of the material and melts it. It cuts the material in the desired shape and is suitable for intricate jobs.

Forming

Forming is a process of shaping metals. The piece you have cut can be shaped by different forming processes. Keep in mind that forming does not involve adding or removing material. It’s all about applying external forces for a permanent change.

Bending: In this process, the working piece is clamped between a die and an external force is applied to change the shape. It takes the shape of the die.

Forging: It involves heating the metal and hammering it to give the desired shape. The hot metal piece is easier to reshape, and the final product has incredible strength.

Rolling: The metal piece passes through a pair of rollers that exert external pressure. It reduces the thickness of the material.

Stamping: In this process, the metal sheet is pressed on a die. It gives it the desired shape in minimal time. It’s suitable for creating identical shapes.

Joining

Joining is the process of binding small metal pieces. The metal pieces you have cut and formed can be joined to make the final product.

Welding: It’s the most common process of joining metals. You can find different types of welding methods, such as Laser Welding, MIG, TIG, and Stick Welding. But in all methods, the metal is heated and melted. Finally, both metal pieces fuse together. On solidification, a strong bond is created.

Brazing: This method joins metal pieces using filler material. The filler material is melted to fill the gaps and join both pieces. Unlike welding, there is no melting of the base material.

Riveting: It involves joining metal pieces using rivets, which are a kind of physical fastener. The rivet is inserted into the metal piece through a hole. The end of the rivet is deformed through hammering to create a strong joint.

Essential Metalworking Tools for Every Workshop

Here are some essential tools you need to have as a beginner and get started with metalworking.

Measuring Tools

Steel Ruler: A steel ruler could help in measuring metal bars and sheets. It’s durable and perfect for marking. It’s suitable for small measurements.

Measuring Tape: A measuring tape is suitable for large measurements. It comes in handy for measuring different types of metals.

Calipers: Calipers are ideal for precise measurements. They can be used to measure thickness, diameter, depth, etc.

Squares: They are perfect for making 90 and 45-degree angles on metal pieces in no time. They are also suitable for measuring the perfect 90-degree angle and depths.

Cutting Tools

Hacksaw: A hacksaw is a hand tool with a fine-toothed blade to cut metals. It can be used for metal sheets, bars, pipes, etc.

Shears: Shears are like scissors. They are for cutting metal sheets. You can make straight cuts in no time.

Angle Grinder: It’s a versatile power tool for cutting, grinding, and polishing metals. It’s a must-have for every metalworker.

Drill Press: It makes holes in the metal workpiece. The metal stays stationary while the drill moves to create the holes.

Shaping Tools

Hammer: It’s a mandatory tool for metalworking. You need different types of hammers for sharing, riveting, and heavy-duty tasks.

Anvil: It’s where you put the metal piece and hit it with a hammer. It helps in shaping, forging, flattening, straightening, cutting, and punching metal pieces.

Files: For removing the minor extra part of the metal and giving it a finish, metal files are necessary. Every metal worker should have a set of metal files.

Joining Tools

Welding Machine: A welding machine is a must-have to start metalworking. Initially, you can go with a simple Stick or MIG welding machine. A multi-process welder would also be a great option, as it can do multiple types of welding. As a beginner, you can also go with laser welding. It’s a bit expensive compared to others, but it is worth it.

Brazing Torch: A brazing torch is a tool for melting the filler material in brazing. It uses acetylene, propylene, or propane as a fuel.

Safety First: Crucial Metalworking Safety Practices

Before you get started with metalworking, it is crucial to understand the safety practices. It must be the priority to avoid any accidents and make metalworking safer.

PPEs

Safety Glasses: You need to protect your eyes from metal shards, debris, and sparks. For welding, you also need an appropriate welding helmet.

Hearing Protection: In applications where the noise is high, consider wearing hearing protection. It will protect your hearing.

Gloves: Heavy-duty gloves are recommended to protect your hands from cuts and burns. During welding, you can use heat-resistant gloves.

Boots: Steel-toed boots are necessary to save the foot from metal, tools, and other heavy objects if accidentally dropped.

Clothing: While using some tools and machines, consider protective clothing to save yourself from fire, cuts, and burns.

Respirators: They are helpful for filtering the air for you. They keep metal debris away from your lungs.

Workshop Safety

Ventilation: Ensure proper ventilation in the workshop to get rid of harmful fumes and airborne particles.

Fire Prevention: Remove all the flammable materials from the work area. Keep fire extinguishers, Class D for metal fires and ABC for general use, ready to deal with any accident.

Safe Tool Operation: Before using a tool, read the manual and learn how to use it properly. Follow the safety instructions. Every time, make sure to inspect the tool for any damage.

Proper Material Handling: Handle metals carefully with the right PPE. Mishandling could lead to serious injuries.

Different Types of Metal and Their Properties

Mild Steel: It’s a type of steel with low carbon. It offers high tensile strength and can be hardened or ductile as required. It is known for its durability. It is suitable for tools, construction frameworks, car bodies, etc. It’s the best metal for beginners for practice and to make simple brackets, shop tools, hooks, small sculptures, etc.

Stainless Steel: It’s an alloy of steel with over 10% chromium. It is preferred over steel because of its corrosion resistance. It looks appealing and suitable for jobs where hygiene matters. Use it for applications where you can’t bear rust. You can use it for a kitchen stand, a corrosion-resistant bracket, any food-processing equipment, etc.

Cast Iron: It is an alloy of iron with 2-4% carbon content. It is very hard and brittle and offers exceptional strength. It’s often used for casting parts and items with complex shapes, such as cookware, engine blocks, and decorative gates. However, it is not suitable for beginners.

Wrought Iron: This is another alloy of iron, but with low carbon content. It’s malleable, ductile, and tough. It is suitable for making gates, railings, and decorative items. Use it when you want to forge something, and it’s not for beginner metalworkers.

Aluminum: It is known for its lightweight, excellent strength, and corrosion resistance. Because of its affordability, it’s widely used. You can use it in brackets, decorative items, tool handles, window frames, etc.

Copper: It’s an excellent conductor of electricity and heat. Usually used in applications where these features are important. It’s also quite malleable and ductile. Other than wiring, it is used in plumbing and roofing. You can use it for jewelry, small trays, decorative items, etc.

Brass: It’s an alloy of copper and zinc. It’s malleable, durable, and corrosion-resistant. It is mostly used in plumbing fittings, handles, and decorative items.

Getting Started with a Simple Metalworking Project

Let’s start with a simple metalworking project that is easy and quick. We’ll share some steps to create a Metal Bracket. You can use the bracket for creating a shelf.

Step 1: There are multiple material options for metal brackets, such as aluminum, stainless steel, and mild steel. The best and most affordable option would be mild steel.

Step 2: Measure the size of the metal and pieces you need to make the desired metal bracket. After that, get ready with the PPEs and take all safety measures.

Step 3: You need to cut the metal pieces. Clamp the metal in your vise. Use an angle grinder or hacksaw to cut to the desired size. Be careful while using these tools.

Step 4: Once you have the piece, it’s time to bend it into an “L” shape. Clamp the piece on the vise and use a hammer to bend it. You can also pre-heat the metal area before hammering, but it is not necessary for mild steel.

Step 5: Use a drill machine to make the holes. Make sure you clamp the metal first and use oil to keep the drill bit cool.

Step 6: Once you’re done, it’s time to give it a smooth finish. Use metal files to smooth the edges. After that, use sandpaper to make it smoother. Finally, coat the bracket with paint to prevent rusting.

Your Metal Bracket is ready. You can use it anywhere you like. But why not make a shelf to keep your metalworking tools and stuff? You just need a piece of plywood, MDF, or wood. Install the brackets, put the board over it, and finally secure it using screws.

xTool Metalfab–Beginner-friendly Metalworking Workshop

xTool’s Metalfab is a laser metalworking machine for beginners. It is meant to make metalworking as easy as woodworking.

It’s a 3-in-1 laser machine. You can do Laser Welding, Laser Cutting/Engraving, and Laser Cleaning. It’s your complete workshop to take your creativity to the next level.

It does not require any prior experience or expertise. It’s a simple machine with beginner-friendly software. One tap can import direct settings for the material and make the job quicker.

With this laser machine, you can achieve incredible precision, speed, and quality. It can precisely cut and weld intricate objects. It also has a CNC cutting and cleaning machine, and you only need to upload the design and press the button. It cuts with exceptional precision in minimal time.

It works on a wide range of metals, such as stainless steel, aluminum, titanium, carbon steel, nickel alloy, brass, galvanized sheet, magnesium, etc. It opens doors to limitless creativity.

Most importantly, Metalfab is equipped with 10 safety features. It has Class 4 Laser Safety certification and is approved by the FDA, FCC, and CE. It’s completely safer for beginners to get started with metalworking.

Conclusion

Whether you are starting metalworking as a hobby, DIY enthusiast, or profession, you need to know the fundamentals. Knowing about the metalworking processes, tools needed, safety standards, and types of metals is essential. We have discussed all these things in detail to lay a strong foundation for your metalworking journey. Once you learn the basics, try your first project because metalworking is all about making something from metal.