What is Sheet Metal Fabrication?
Sheet metal fabrication is the process of shaping sheet metal into desired shapes by using various tools and processes. Sheet Metal Fabrication is used in a variety of industries, including automotive, aerospace, and construction. From custom car parts to computer housings and aircraft wings, the potential applications are nearly endless.
Sheet metals manufacturer companies in India are well known for their premium quality products and services. These sheet metal components manufacturers in India have been providing high-quality sheet metal components at affordable prices.
There are many different processes involved in sheet metal fabrication, but the most common ones are cutting, bending, and welding.
Creating Engineering Drawings and 3D modelling is the first step of sheet metal fabrication. It is a requirement to create drawings for manufacturing. Before any work can begin, engineers need to develop blueprints and design files. These modelling files will determine the specifications of the sheet metal needed to make component.
First, the metal sheet is cut to the desired size and shape using a cutting tool, such as laser cutter, or waterjet. Cutting the sheet metal is important because it makes the metal easier to shape and manipulate. We can also use presses to produce pre-cut shapes in the material, such as holes, slots, circles, and hexagons.
Next, the sheet is bent into the desired shape using a press brake or roller. Forming is the process of using die tools to shape the metal into the desired form. Bending, drawing, and deep drawing are three of the most common techniques used during forming.
After forming has been completed, assembly is the process of joining multiple pieces of sheet metal into one. This can be achieved through welding, riveting, or bolting. The sheet is welded together using an arc welder, spot welder, MIG Welding, TIG Welding or Laser welding.
Finally, finishing is the process of treating the metal’s surface to increase corrosion resistance and improve its visual appearance. Finishing process can include powder coating, chroming, sandblasting, or painting. Depending on the desired results, different finishing techniques will be used.
Also, there are several types of sheet metal fabrication processes, each with its own advantages and disadvantages. Some of them are stamping, laser cutting, waterjet cutting, and CNC punching.
Difference between Sheet Metal Fabrication and Machining
| It involves the shaping and forming of sheet metal into components, such as boxes, enclosures, and brackets |
| Suitable for metals which are typically thin, strong and rigid, and can range from very thin aluminium or steel, to thick, thick stainless steel sheets. |
| Requires a lot of skill and knowledge of metalworking principles |
| Produces relatively simple parts and components, |
| Less expensive due to its simpler operations and machine requirements |
| It is a process of removing material from a piece of metal to create parts such as nuts, bolts, and structural components. |
| It can be used to work with any metal, including aluminium, brass, steel, and many others |
| Uses metalworking machine tools such as lathes and milling machines to cut, grind, and shape metal. |
| Produces more complex parts and components |
| More expensive process |
MATERIALS
Zastata uses a variety of materials for Sheet metal Fabrication process, each with its own unique set of properties to produce various types of products and items.The most common metals used in this process are
Steel – The most popular metal used in the fabrication of sheet metal is Steel. It is strong and can easily cut, bend, and formed to the desired shape. It is also corrosion resistant which makes it an excellent choice for outdoor applications.
Stainless steel – Stainless steel is a type of steel that contains a high level of chromium and nickel, making it highly resistant to corrosion. We can also provide other treated options like Non-treated / Galvanized Steel too.
Copper– Due to its good electrical conductivity and strength, copper is easy to weld and form into shapes and is extremely corrosion resistant. It is also a relatively lightweight metal, making it well-suited for products that need to be lightweight without sacrificing strength.
Aluminium – It is another popular choice for sheet metal fabrication due to its lightweight properties and corrosion resistance. Additionally, it’s malleability makes it easier to form into the desired shape.
Titanium – It is selected for its strength to weight ratio, corrosion resistance, and machinability. Titanium is lighter and stronger than many types of steel, making it a good choice for parts that need to stand up to extreme conditions without being too heavy. Additionally, titanium has a low thermal conductivity, making it ideal for intricate parts that need to maintain a consistent temperature.
Brass – Brass is often used in sheet metal fabrication for to its strength and malleability. Though this metal is not as corrosion resistant as other metals, it does have excellent electrical and thermal conductivity, making it a good choice for electrical components. Additionally, brass is very easy to machine, drill, and form, so it can easily be used to create complex products.
The best choice for any project will depend upon the desired strength, corrosion resistance, and other properties. Regardless of the type of metal, sheet metal fabrication can be used to create products ranging from simple plates to complex components and products.
Zastata also provides assembled finished product with a range of finishing operations to enhance material properties.
Surface finishing is another important aspect of sheet metal fabrication. The finished metal surface has both aesthetic and functional benefits.
- Sand Blasting – This method involves the shooting of sand or other abrasives against the sheet metal at high speed. Thus, it gives the sheet metal a matte texture finish and prepares it for coating.
- Powder Coating – It is done by directly spraying of powdered paint onto the metal part. This is followed by baking the product in an oven which help to form a wear-resistant layer.
- Anodizing – Anodizing helps to give a component with excellent resistance to corrosion. It also improves the durability and hardness of the surface. It also helps the parts to look more attractive, and makes them last longer.
- Chemical Films – These are finishes that provide good conductivity properties and corrosion resistance. This coating process serves best for a base while painting, and it gives a golden surface finish.
The quality of the final product is largely determined by the accuracy of the process and the thoroughness of inspection. Zastata also performs several different methods used to inspect parts and components made from sheet metal.
The most common inspection methods are
- Visual Inspection: Visual inspection of the part is also an important inspection technique. This involves inspecting the part with the naked eye, looking for surface abnormalities and defects, such as scratches, dents, or burrs. Visual inspection is not always sufficient, and other methods, such as magnified visual inspection, may be needed to detect very small defects.
- Destructive testing: It may be used to inspect sheet metal parts. This involves subjecting the part to a variety of tests that may cause it to be destroyed but can also be used to evaluate various properties of the component and its materials. Such tests may include tensile testing, hardness testing and fatigue testing.
- Gauging: Gauging can be used to check the dimensions of a component against the customer’s specifications, as well as for checking tolerances. This involves the use of measuring tools such as CMM, calipers, micrometers and surface gauges to measure the size and shape of the component.
- X-ray inspection: This is more accurate than visual inspection, but it is also more expensive. This method is used to check for internal defects such as voids and inclusions.
- Ultrasonic inspection: It is the most accurate method, and also the most expensive comparatively. This method uses sound waves to check for defects.
Sheet metal fabrication requires robust and reliable inspection methods to ensure that the final product meets customer requirements.
By regularly inspecting parts and detecting any flaws prior to use, Zastata can ensure that their components meet the desired quality for a variety of industries.
Quality Documentation
Zastata has good understanding and experience with Quality documentation like:
APQP – Advanced Product Quality Planning
FMEA – Failure Mode Effective Analysis
PPAP Level 3 – Production Part Approval Process
SPC – Statistical Process Control
MSA – Measurement System Analysis
Quality Certifications
We work with manufacturers who hold certifications like:
ISO 9001:2015 (Quality Management System)
ISO 14001:2015 (Environmental Management System)
ISO 45001:2018 (OH & SMS)
AS9100 Rev C (Aviation, Space and Defence)
ISO13485:2016 (Medical Devices)
IATF16949:2016 (Automotive Quality Management System)
OTHER TYPES OF METAL FABRICATION
Whilst Pressure die casting is widely used casting method for high volume production, there are other casting methods which have their merits
OUR MANUFACTURER LOCATIONS
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
COUNTRIES WE EXPORT
Over the years, Zastata has audited and worked with various die casting manufacturer across India for various casting types. Our pressure die casting company are selected and retained based on their quarterly quality performance on Cost, Delivery, Quality, Communication, Innovation and flexibility.
UK
USA
AUS
Denmark
Germany
Canada
France
China
INDUSTRIES WE SERVE
Advantages:
- Ability to produce strong, complex parts with tight tolerances.
- MIM parts are also less expensive than parts made with other methods, such as machining or investment casting.
- Cost effective, more versatile, and repeatable, making it an ideal choice for mass production for various shapes and size.
- Products made using plastic injection molding are often very strong and durable.
- Smooth Surface finish.
Applications
This process can be used to create a wide variety of products in a various industries with greater design flexibility, from car parts to kitchen appliances.
- The aerospace industry also relies heavily on sheet metal, as it is used to create aircraft fuselages, parts for support structure such as the sidewalls on commercial aircraft and the body of fighter planes.
- In the automotive industry, sheet metals are used to create car bodies and other essential parts namely, body panels, exhaust systems, hoods, door handles, grills and other lightweight components.
- The medical industry also utilizes sheet metal fabrication, as it is often used to create implants and other medical devices.
- It is used to construct kitchen appliances such as ovens, microwaves, stoves, and ventilation systems.
Sheet metal fabrication is a multi-purpose manufacturing process that can make the most of both lightweight and rigid materials.
It requires a skilled fabricator to reap the benefits of this process and Zastata makes sure that audited manufacturers with right certifications and manufacturing capabilities are used. Zastata takes care of end to end process from supplier selection to freight management. We work as part of your organisation to be mutually beneficial.
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