Metal Fabrication: A Comprehensive Guide to Processes, Techniques, and Applications
Heard "Metal Fabrication" a gazillion times, but not sure what it exactly means?
Metal fabrication is the ancient art of creating metal products. From raw materials to the finished design, it is responsible for everything.
This comprehensive guide on metal fabrication covers everything from processes to techniques and applications to the foreseeable future.
We will take you through the core metal fabrication process to explain how it works. We will share the key applications in different industries to highlight the scope of metal fabrication and its future.
What is Metal Fabrication?
Metal fabrication means turning raw metal materials into finished metal structures or products. It involves various metalworking techniques, such as cutting, bending, welding, forming, assembling, etc.
It started in ancient times when metals were discovered. At that time, simple techniques, such as hammering, were used to shape the metal. Now, the raw metal is shaped and transformed into the desired form by going through a wide range of advanced processes.
Metal fabrication is the backbone of the modern industry. From construction to automotive and consumer goods to aerospace, it's an essential part of any industry. It's a mixture of art and science that empowers us to turn ideas into reality using skills.
Things you see every day are a gift of metal fabrication. Be it car parts, hand tools, cutlery, metal doors, screws/bolts, or any metal you see that has been processed to get the desired form, that is what metal fabrication offers.
Core Metal Fabrication Processes: How It's Done
Metal fabrication involves various processes to get the finished products. However, the core processes that are used in almost every metal fabrication job are as follows.
Cutting
Cutting is the first process in which the fabricator separates a piece of metal into the desired size or shape from the raw material. Suppose there is a large steel sheet to make the front door. The worker will mark the size needed and use a tool to cut the sheet.
Through cutting, the raw material is divided into manageable pieces that go through further processing. Fabricators can use various cutting techniques, depending on the application.
Here are some common cutting methods.
Shearing
Shearing is a simple cutting process to cut the desired size from metal sheets. You can do it using a simple manual shear that looks like scissors. The sharp blade is quite useful for making straight cuts.
Metal shears are available in different shapes and sizes. For normal use, shears that look like scissors are enough. However, for heavy-duty tasks, sharp blades are fitted on a manual machine that has a long handle to control the blade. There are also automated machines for cutting large sheets.
Nowadays, fabricators use power tools for shearing. They make cutting metal sheets a breeze.
Sawing
Sawing requires a sharp-toothed blade to cut metals. It can cut sheets, bars, pipes, etc. It is a more versatile option. From manual saws to power saws, there is a wide range of sawing tools, such as band saws and cold saws.
Laser Cutting
Laser cutting is an advanced technique that uses a highly focused beam of laser to cut metals. It is an extremely precise and fast technique and ideal for intricate and delicate jobs.
Usually, a laser torch is attached to a CNC machine. It can automatically cut intricate shapes with exceptional precision. You can cut any design on metal sheets and use the machine for mass production.
Plasma Cutting
Plasma cutting uses a jet of ionized gas at an extremely high temperature, which can even be over 20,000⁰C. It can instantly melt metals and cut them in no time. It offers excellent precision and speed. It is suitable for cutting conductive materials like steel and aluminum.
Waterjet Cutting
Waterjet cutting uses a high-pressure stream of water mixed with abrasive particles to cut metals. The best thing about this method is that it does not increase the temperature like laser or plasma cutting. It can cut delicate metals without affecting the surrounding area. It can be used for a wide range of metals.
Forming
After cutting, fabricators turn the metal piece into the desired size and shape through forming. It involves bending, pressing, forging, and various other methods to change the shape of the metal. The final form is achieved without adding or removing the material.
In different methods of forming, the metal is reshaped by applying external force. It permanently changes the shape of the material.
Here are a few common forming methods used in metal fabrication.
Bending
Bending reshapes the metal pieces by exerting pressure. The metal piece is clamped between a punch or die. It is bent at different angles according to the desired shape.
A press brake is a common machine used for this purpose. It can exert immense pressure to permanently change the shape of the material. Depending on the use case, you can use mechanical, hydraulic, service, or CNC press brakes.
Rolling
In rolling, a metal piece is passed through a pair of rollers. It is mainly used to reduce the thickness of the metal piece and stretch it. It exerts pressure to form sheets or thin metal pieces of the desired dimension.
Rolling mills and roller tables are used for this purpose. A simple example is jewelry makers using a piece of gold to turn it into the desired thickness.
Stamping
Stamping is a widely used process to create identical metal pieces. It can change the shape of the metal with the help of a die.
The pressure is exerted on the metal sheet, and it is pressed on the die to adapt to a specific shape. It is used for creating shapes, patterns, and holes.
Punching
Punching is a process of making holes in a metal piece. It uses a special die with sharp edges. When the die is pressed on the metal sheet, it cuts the shape or hole. It offers precise holes with smooth edges in minimal time.
It is not limited to shots. It is possible to use slots and custom-shaped openings. All you need is a die of the shape you need.
Forging
Forging is an old technique to change the metal shape by hammering and temperature change. Blacksmiths forge metal shapes by hammering a hot metal piece. Modern forging is done through heating the object in a furnace and then using a forging press.
The process offers incredible strength and durability. It is suitable for long-lasting components.
Casting
Casting refers to pouring melted metal into a mold. Once the metal solidifies, you get the desired shape.
It is a slow process, but it offers excellent strength.
It is ideal for making complex parts with intricacies. Because of the mold, you get the same shape every time with minimal effort.
Joining
Through joining methods, fabricators put all their pieces together to create the final product. It is like an assembly process. The metal pieces you have cut and formed can be joined through the following techniques.
Welding
Welding is the most common method of joining metal pieces. It melts the metal pieces and creates a permanent bond between them. The strength it offers is incredible as it fuses both metals and joins them just like one piece.
Fabricators opt for different types of welding methods depending on the type of metal, precision, speed, etc.
SMAW (Shielded Metal Arc Welding) or Stick Welding is a common and low-cost method of joining metals. It uses a consumable electrode that is coated with flux. When you strike the metal piece with the stick, it creates an arc and generates immense heat that melts the metal and creates a weld pool. It is suitable for heavy metal fabrication, construction, repairs, etc. It can work outdoors and join thick and rusty materials.
MIG (Metal Inert Gas) Welding is one of the most commonly used welding methods these days. It is beginner-friendly and offers exceptional weld quality and speed. It's a semi-automatic process because the torch has an automatic wire feeder that is used as a filler material. The welder just needs to pull the trigger and take the torch near the welding piece. It is used where aesthetics matter, such as in automotive manufacturing, robotics, aerospace, etc. It is suitable for indoor jobs only.
TIG (Tungsten Inert Gas) Welding uses a non-consumable tungsten electrode. The welder has to hold the torch in one hand and the filler material in the other. It's a bit difficult, but it offers exceptionally clean and precise welds. It is used for aerospace, aircraft, and automotive applications. It can offer excellent strength and can be used for delicate materials.
Laser Welding is the latest and most advanced technology compared to others. It uses a powerful and focused laser beam to increase the temperature of the material and melt it. It is capable of creating strong bonds in no time. It is an ideal option for mass manufacturing because of speed. It is perfect for delicate and intricate jobs. Most importantly, the cost of laser welding is much lower, which is the reason industries are opting for laser welding.
Brazing
Brazing is also a joining method for joining metals. In this process, the metal is not melted. Instead, a low-temperature filler material is used to join metals and fill the gaps. A brazing torch increases the temperature of the metals to be joined, and the filler material is applied. The joint is not as strong as welding, but it is still strong enough to bear some load.
Fastening
Fastening is a process of joining metals using mechanical fasteners, such as rivets, bolts, and screws. It is quick and easy and does not require heavy equipment.
You can find non-permanent fasteners, such as bolts & nuts, screws, and washers. These can be removed whenever needed. Permanent fastening can be done with rivets and clinching.
Adhesive Bonding
Adhesive bonding is an alternative method for joining metals. It uses chemical and physical forces to join metal pieces. It can be used for applications where aesthetics matter. It offers some advantages, such as joining of dissimilar metals, vibration/noise dampening, and corrosion resistance.
It can be used for applications where welding and fastening are not suitable. Keep in mind that adhesives, such as epoxies, acrylics (MMAs), and polyurethanes, require time for curing. They also have some limitations, such as temperature and environment. They degrade over time and do not have the strength of welding.
Finishing
After joining all the metal pieces and achieving the final design, finishing is what makes it look aesthetically pleasing. Not only does it enhance the appearance, but it also enhances durability and functionality.
After finishing, the metal becomes more resistant to corrosion. It is able to last longer and bear more wear and tear. It is also necessary for safety.
Grinding
Grinding uses an abrasive element to smooth the surface. If there is any sharp edge or pointed area, it makes it smooth and clean. It removes the excess and makes the whole metal piece shinier and smoother.
Sandblasting
Sandblasting is a quick way to clean the surface. It uses abrasive particles, such as sand, with high pressure to remove the layer of rust, paint, or any impurity on the surface. It brings out the real face of the metal.
Powder Coating
Powder coating enhances the aesthetics and durability of the metal piece. A dry powder is applied to the metal through an electrostatic process. Then, it is baked in an oven to harden the powder and create a durable layer. Fabricators can pick any color they want and increase the life of the metal product.
Painting
Painting is the simplest finishing technique. It improves the appearance of the metal and also provides it with some sort of protection. It's affordable and quick. However, it is not as durable as power coating.
Key Applications and Industries
Construction and Architecture
Metal fabrication is widely used in the construction and architecture industry. We can say that the construction industry is one of the largest consumers. Metal is used in the making of building structures, railings, doors, staircases, roofs, etc.
In architecture, it is used in structural components, facades & cladding, decorative ornaments, and a lot more. Be it making a house, building, bridge, stadium, or anything, it needs metal fabrication. From Burj Khalifa to Shanghai Tower, metal fabrication is the backbone of these architectural innovations.
Automotive and Aerospace
The automotive sector starts and ends at metal fabrication. From creating the body chassis to body panels, engine to exhaust, and seat belts to airbag systems, all of these require metal fabrication. Be it a large or small engine component, metal fabrication is what is behind an automotive vehicle.
Similarly, the aerospace industry also uses advanced metal fabrication. Firstly, for the making of aircraft bodies that are solely made of metals. They included almost every metal fabrication process, such as bending, forming, welding, riveting, etc. Other than the structural components, metal fabrication is useful in engine components, interior elements, etc.
Consumer Products
Be it your refrigerator, oven, air conditioner, smartphone, or modern furniture, wherever you look, you will find the applications of metal fabrication. The bodies or components of most consumer products are made through metal fabrication.
Energy
In the energy sector, metal fabrication is a vital component. It is used in making wind turbines, generators, storage tanks, solar panel frames, oil & gas pipelines, etc. We need metalworking to keep the industry running.
Industrial Machinery
Pick any industrial machine, and you'll notice it is made of metal from top to bottom. Even metal fabrication machines are also made by metal fabrication. There are countless applications, from heavy machinery to processing equipment. For instance, bulldozers, excavators, conveyors, robotic arms, cranes, and forklifts are all made through metal fabrication.
Medical
The medical industry also relies on metal fabrication in almost every space. From surgical tools to medical devices, hospital equipment to diagnostic machines, almost everything is made from metal. Even if metal is not used to make the exterior, it is used in the interior components.
Choosing a Metal Fabrication Partner: What to Look For
A metal fabricator needs a perfect partner, which is none other than a metalworking machine. xTool Metalfab could be an excellent choice. It's a 3-in-1 metalworking machine that can do laser welding, cutting/engraving, and cleaning. It's a complete metalworking workshop to make metal fabrication easier and quicker.
Compact Yet Powerful
Metalfab is a compact laser machine that can fit easily in your garage. However, it offers industrial-grade power. Its 1200W and 800W laser machines are ideal for most applications. It can weld up to 5mm of metal and cut up to 10mm of metal sheets in only one pass. It works 8X faster than a MIG welder, which cuts at 400m/s.
User-friendly
The machine is super user-friendly. It is an excellent choice for beginners as well. It does not require expertise or experience; just minimal knowledge to operate the machine.
Its software is easy to use. Users just need to select the materials, and it automatically selects the optimal settings. Just upload the design and press the button, and it will cut the metal on its own.
Exceptional Precision
xTool Metalfab offers incredible precision. Its focused laser beam offers aesthetically pleasing, strong welds. It minimizes the heat-affected zone to 0.002 inches, which means it only targets the area to be welded, and the surrounding area remains safe. It has an impressive accuracy of 0.1mm, which ensures flawless results every time.
AI and Automation
The machine automates the metal cutting and cleaning processes. Users only need to upload the design, and it does the rest. Through AI, it has become smart. It can control the movement of the laser head with extreme precision without any vibrations.
It assesses the changing height of the material and adjusts the laser position for excellent results. It also dodges obstacles on its own. Using AI, it analyzes the material and generates an optimal layout in one click to utilize up to 98.7% of the material.
Safety and Certifications
Metalfab has Class 4 laser safety certification. It is also CE, FCC, and FDA certified. It is equipped with 10 safety features to make laser welding, cutting, and cleaning safer than ever before. It has an emergency stop button, a USB safety key, an electrical safety design, drip detection, 3-zone real-time temperature monitoring, a light filtering cover, an exhaust fan detection, etc. It's perfectly safe to use even for beginners.
The Future of Metal Fabrication
Metal fabrication is the essential element of the modern industry. Over time, it is also getting advanced with modern technologies, equipment, tools, etc.
Automation is one of the prominent trends in metal fabrication. Companies are opting for automated processes to make the process faster and safer. It increases efficiency and, at the same time, offers incredible precision.
Robotics is the future of metal fabrication. It's already been a major part of large industries like automotive, electronics, and logistics. It makes things easier and faster while reducing the chances of errors.
Metal fabrication is getting more simplified with 3D printing. Now, it is possible to make any intricate metal piece with it. It is an ideal option to make complex metal parts with incredible precision. This is the future of fabricating extraordinary metal products.
Last but not least is the AI design optimization. Like xTool Metalfab, companies are using AI to help reduce waste and create a design that stands out. The AI saves time and helps in designing almost anything.
Conclusion
Metal fabrication is the backbone of industries. It's what makes them capable of using metal to make innovative products. From a small home to a skyscraper and from a motorcycle to an aircraft, metal fabrication is almost everywhere.
It's an art and science of shaping and redesigning raw metal as per their needs by going through different metal fabrication processes, as we've discussed. The applications are limitless, and the future is bright. And this is what makes it an ever-demanding sector.
