Sheet Metal Fabrication
Sheet metal fabrication turns flat metal sheet (0.5–6mm typical, up to 20mm with heavy equipment) into bent, welded, and assembled parts. Laser cutting handles the flat pattern, press brake bends the flanges, welding joins the pieces. The default process for enclosures, brackets, frames, panels, and structural parts where forming is faster and cheaper than machining from solid. For design best practices, see our Sheet Metal DFM Guidelines
Sheet Metal Fabrication Capabilities
| Feature | Description |
| Maximum Part Size | 3000×1500mm (laser cutting)／Custom sizes available |
| General Tolerances | Metals: ISO 2768-m (bending)／Laser cut parts: ±0.1mm typical |
| Precision Tolerances | To drawing specifications and GD&T annotations, tighter than ±0.1mm achievable |
| Material Thickness Range | 0.5mm–20mm |
| Standard Lead Time | 5 business days (simple parts as fast as 1 day) |
| Processes | Laser Cutting, Punching, Press Brake Forming, Welding, Hardware Insertion |
| Post-Processing | Surface Finishing |
| Type | Material | Service | Process | More Info |
|---|---|---|---|---|
| Aluminum | 5052-H32 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet | Selection Logic |
| Aluminum | 6061-T6 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet | Selection Logic |
| Stainless Steel | SUS304 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet | Selection Logic |
| Stainless Steel | SUS430 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet | Selection Logic |
| Cold-Rolled Steel | SPCC / ASTM A1008 (CS Type B) | Sheet Metal Fabrication | Cutting / Forming | Data Sheet |
| Galvanized Steel | SGCC / ASTM A653 G90 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet |
| HSLA Steel | HC340 / ASTM A1011 HSLAS 340 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet |
| HSLA Steel | HC420 / HSLAS 420 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet |
| Structural Steel | SAPH440 / ASTM A1011 SS Gr.50 | Sheet Metal Fabrication | Cutting / Forming | Data Sheet |
(Coming Soon)
Materials Supported
Common Metal Materials
Aluminum sheet is light, bends clean, and takes anodizing well. 5052 is the go-to for enclosures, panels, and brackets, it bends without cracking even at tight radii. 6061 is harder and stronger but splits on sharp bends; use it where the flat features matter more than the formed ones. 7075 is rarely worth it in sheet metal, the strength gain doesn’t justify how poorly it forms.
Stainless steel sheet holds up in wet, corrosive, or food-contact environments where mild steel would rust through. 304 covers most applications: enclosures, brackets, and structural panels. 316 adds molybdenum, which matters in saltwater exposure or chemical handling. Stainless work-hardens fast; bend angles need to account for springback, and tight radii crack more readily than on mild steel.
Carbon steel (mild steel) is the default for structural sheet metal parts where corrosion isn’t a concern. It bends predictably, welds without fuss, and costs less than stainless or aluminum. Most brackets, frames, and enclosures that will be powder-coated or painted go in mild steel. SPCC and Q235 are the grades that show up most in fabrication.
Brass sheet machines and forms well, and the surface finish holds up without coating. It shows up in decorative panels, electrical terminal plates, and parts where low friction matters at contact points. Springback on brass bends is moderate, tighter than steel but looser than aluminum.
Copper sheet is used where electrical or thermal conductivity is the main requirement, bus bars, heat spreader plates, and grounding straps. It’s soft and forms without cracking, but scratches easily. Leave a protective film on until final assembly.
Material Selection Guidance
Pick the material based on what the part actually needs to do. Mild steel and galvanized steel keep cost down on brackets, enclosures, and structural frames. Stainless 304 or 316 handles wet environments and chemical exposure where mild steel would rust. 5052 bends without cracking on tight radii; 6061 is harder but machines cleaner after forming. Titanium shows up in aerospace brackets or medical hardware, for most sheet metal work it’s overkill.
Lock in the material before finalizing bend radii and finish specs. Weldability and surface treatment interact. Changing material late shifts the whole process.
Tolerances & Precision
Not every bend and hole needs a tolerance callout. Laser-cut holes hold ±0.1mm without extra cost. Bent flanges drift more, if that dimension matters, call it out on the drawing.
| General Tolerances | Metals: ISO 2768-m (bending); Laser cut parts: ±0.1mm typical |
| Precision Tolerances | Can manufacture and inspect to drawing specifications and GD&T annotations, including tolerances tighter than ±0.1mm |
| Min Material Thickness | 0.5mm |
| Max Material Thickness | Up to 20mm (depending on material and process) |
| Min Hole Diameter | Equal to material thickness (min 1mm) |
| Maximum Part Size | 3000×1500 mm (laser cutting); custom sizes available |
| Minimum Bend Radius | 0.5× material thickness |
| Production Volume | Prototyping: 1-100 pcs Low volume: 101-10,000 pcs High volume: Above 10,001 pcs |
| Lead Time | 5 business days for most projects. Delivery of simple parts can be as fast as 1 day. |
Surface Finishing Options
Powder Coating
Most common finish on steel and aluminum sheet metal parts. Dry powder applied electrostatically, then cured at 180–200°C for 20 minutes. Builds 60–100μm thickness, covers full RAL color range, matte to high-gloss options. Standard outdoor finish for enclosures, frames, and structural panels resists UV, chips, and corrosion.
Anodizing
Aluminum sheet metal only. Type II builds 5–25μm color layer for decoration plus basic corrosion resistance, black, clear, red, blue, gold available. Type III hard anodize builds 25–75μm wear-resistant layer, stays gray or black.
Mask threaded holes and PEM nuts before anodizing; coating buildup affects thread fit.
Zinc Plating
Standard corrosion protection on carbon steel sheet metal at lower cost than powder coating. Builds 5–15μm thickness, adds minimal weight and doesn’t affect tight dimensions. Yellow chromate seal extends salt-spray resistance to 96–240 hours. Used for internal brackets, fasteners, and frames going into light-corrosion environments.
Brushed Finish
Abrasive belt drawn across the surface in one direction. Creates linear grain pattern on stainless steel and aluminum panels at Ra 0.4–0.8μm. Grit 120–240 produces #4 architectural finish, standard on kitchen appliances, elevator panels, and stainless enclosures. Holds up without coating; fingerprints wipe off with stainless cleaner.
Design Guidelines
A part can be perfectly foldable on paper and still come back with cracked bends, misaligned holes, or a cost three times the estimate. Good design for sheet metal means the flat pattern nests cleanly, the bends don’t fight the material grain, and the holes land where a punch or laser can actually hit them.
| Core DFM Principles | Better sheet metal design means: – bend radius matched to material thickness – hole diameter larger than material thickness – consistent bend direction where possible – relief cuts at corners to prevent tearing – tolerances called out only on features that actually matter |
| Bend Radius | Minimum inside bend radius is typically 1× material thickness for mild steel and stainless, 1.5× for aluminum. Going tighter risks cracking the outer face, especially on 6061. Larger radius costs nothing extra and reduces scrap. |
| Hole Size and Placement | Small holes and deep holes are common machining cost drivers. The design guidance Hole diameter should be at least equal to material thickness. Smaller punches deflect and break under press load. Edge distance from hole to nearest bend should be at least 2× material thickness, smaller punches deflect and break. Keep holes at least 2× material thickness from any bend line. Holes too close to a bend distort when the flange forms. |
| Bend Relief | Add bend relief cuts at corners where two bends meet. Without relief, the metal tears or warps at the intersection. Relief width should match material thickness; depth should clear the bend zone. |
| Flange Length | Minimum flange length is around 4× material thickness. Shorter flanges can’t be gripped by the press brake die and produce inconsistent angles. |
| Avoid Unnecessary Precision | Sheet metal formed parts hold ±0.1mm on laser-cut features and roughly ±0.5° on bend angles under standard tooling. Calling tighter tolerances on bent flanges drives up inspection time and scrap rate without improving function in most assemblies. Mark only the dimensions that actually affect fit or function. |
Typical Applications
Concept Models
Early visual and tactile models that lock in form, proportion, and styling before any tooling is committed.
Functional Prototypes
Working parts in production-intent materials, built to verify fit, function, and mechanical performance under real loads.
Engineering Validation
Rigorous testing of strength, durability, and environmental resistance to confirm the design meets performance and safety targets.
Fit & assembly testing
Dimensional and mating checks across components to verify tolerances, clearances, and assembly before scale-up.
Market testing samples
Near-final, cosmetically finished units in small batches for customer, retailer, and certification feedback.
Bridge production
Limited pre-mass runs on near-final tooling that keep you shipping while hard tooling and full production ramp up.
Equipment & Capacity
Knowing what equipment a shop runs tells you what it can actually handle. For sheet metal, the split that matters is whether laser cutting, punching, and press brake forming are all in-house, or whether bending and welding go to a subcontractor. That gap shows up in lead time and dimensional consistency on assembled parts.
Quality Control Flow
Incoming inspection
Sheet stock checked for thickness tolerance (cold-rolled steel ±0.05mm, aluminum ±0.1mm), surface defects, and material grade. Mild steel SPCC vs SECC look identical but bend differently. Stainless verified for grade 304 and 201 are visually indistinguishable but corrosion performance differs significantly.
In-process inspection
First-article check after laser cutting, after bending, and after welding. Bend angles verified with protractor or CMM on each setup change, press brake springback varies by material batch. Welded assemblies checked for distortion and dimensional drift before moving to finishing.
Final inspection
Dimensional check on overall envelope, hole positions, and bend angles. Hardware insertion verified for thread integrity (PEM nuts gauged with bolt). Welds inspected for porosity, undercut, and spatter under controlled lighting. Powder-coated parts checked for coating thickness (60–100μm) and coverage on edges.
Documentation and traceability
Material certs, cutting reports, weld procedure records, and final inspection logs archived per lot. Parts trace back to material heat number, machine, operator, and inspection record. PPAP, ISIR, and first-article documentation available for automotive, medical, and aerospace customers. ISO 9001:2015 certified quality system.
Related Solutions
Rapid Prototyping
Low Volume Production
Production Tooling
End-to-End Manufacturing
Sheet Metal Fabrication: Common Questions
What file formats do you accept for sheet metal parts?
STEP and DXF are preferred. STEP carries full 3D geometry including bends and hardware; DXF works for flat patterns. PDF drawings are required alongside the 3D file for bend angle callouts, tolerances, hardware specs (PEM nuts, standoffs), and surface finish requirements. If you only have a 2D drawing, send it and we will confirm feasibility.
What sheet thickness range can you handle?
0.5mm to 6mm covers most enclosures, brackets, and panels. Up to 20mm is available with heavy press brake equipment for structural parts. Standard stock runs in 0.5, 0.8, 1.0, 1.2, 1.5, 2.0, 2.5, 3.0mm. Non-standard thickness is available on request with longer lead time.
Which materials are available for sheet metal fabrication?
Aluminum: 5052-H32, 6061-T6. Stainless steel: SUS304, SUS430. Cold-rolled steel: SPCC (ASTM A1008). Galvanized steel: SGCC (ASTM A653 G90). High-strength low-alloy steel: HC340, HC420, SAPH440. If your spec calls for a different alloy or temper, include the material standard in the RFQ and we will confirm availability.
What processes are included in your sheet metal service?
Laser cutting (flat pattern), CNC press brake bending, punching, hardware insertion (PEM fasteners), TIG/MIG welding, deburring, and surface finishing. Parts that require both machined features and sheet metal forming can be handled in-house by combining sheet metal and CNC machining workflows.
What tolerances can you hold on bent sheet metal parts?
Laser cut profiles hold ±0.1mm on flat features. Bend angles hold ±1°. Hole-to-bend dimensions typically run ±0.2–0.3mm depending on material and thickness. For tighter requirements, note the critical dimensions on the drawing and we will review during DFM. Springback compensation is applied per material during programming.
What surface finishes are available?
As-fabricated, bead blast, powder coating (any RAL color), anodizing (aluminum only, Type II or Type III), zinc plating, nickel plating, electrophoretic coating (e-coat), and passivation for stainless. Specify finish and color in the drawing or RFQ. For powder coat, include RAL number or a Pantone reference.
What is your minimum order quantity?
No minimum. Prototype quantities of 1 to 5 pieces run on the same laser and press brake as production orders. Per-part cost drops with volume. If you are comparing prototype versus production pricing, include both quantities in the RFQ and we will quote both tiers.
How long does it take to get sheet metal parts?
Simple laser-cut flat parts in standard materials ship in 3 to 5 business days from drawing approval. Multi-bend enclosures or parts with welding and powder coat run 7 to 12 days. Production orders are quoted with lead time based on quantity and finish. DHL/FedEx express delivery to North America and Europe is standard.
Do you sign NDAs before reviewing design files?
Yes. Send an NDA request to [email protected] before uploading files. We return a signed copy within 24 hours on business days. Files can also be uploaded through our secure RFQ portal.
Can you handle welded assemblies, not just individual parts?
Yes. TIG and MIG welding for aluminum and steel assemblies. Provide an assembly drawing with weld callouts (weld symbol, throat size, joint type). If you need post-weld machining on mating faces or mounting holes, that can be handled in-house. Include assembly requirements in the RFQ so we can quote the full scope.
Ready to Quote Your Sheet Metal Part?
Upload your STEP or DXF file and get a DFM review + quote within 12 hours. No tooling cost. Minimum 1 part.
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