Metal fabrication refers to manipulating metal to form some kind of component or end product. The term encompasses an incredibly wide array of applications, from building anvils, to metal stamping, to making wrought iron gates. In fact, anything that involves using metal to create a component or end product involves metal fabrication.

This article focuses on sheet metal fabrication, which is the cutting, bending, rolling, welding, forming, and stamping of sheet metal to make something usable, like a component for a larger piece. Metals used include stainless steel, aluminum, etc.

Components Created

Components created through metal fabrication are used in many applications, including kitchen and sanitary equipment, HVAC components, and machine tools.

There are three basic categories to metal fabrication: cutting, forming, and finishing.

Cutting

Cutting sheet metal refers to the numerous ways in which metal can be cut into smaller pieces, which is then formed or molded into the final piece. Usual techniques for cutting include:

• Shearing - used for cutting large pieces into smaller ones using shear stress on a machine.
• Electrical Discharge Machining (EDM) - uses a charged thin electrode, surrounded by ionized water, to cut conductive materials. The electrode's spark melts the metal.
• Laser Cutting - uses lasers to cut very precise, complex pieces.
• Water Jets - use high pressure water (20,000-60,000 psi); good because no heat is generated during cutting.
• Abrasive Cutting - uses saws or grinders to cut sheet metal.

Forming

After it's cut, sheet metal must be formed into the shapes needed for the component as the step before final finishing. Forming techniques include:

• Rolling - uses a series of roll stands to shape a flat piece of sheet metal over and over.
• Bending & Forming - used by hand to manipulate the metal into the desired shape.
• Stamping - uses dies and tools to stamp a design, including 3-D designs, into the metal.
• Punching - punches holes in the sheet metal.
• Welding - joins metals by melting a bond between materials.
• Hardware & Fastener Creation - integrates handles and latches into the sheet metal.

Finishing

To finish a component, its sharp or rough edges may then be polished using an abrasive. It then goes on to its final purpose. If it is a smaller component of a larger piece, say part of an HVAC system, it may then continue on to be attached to the larger system.