Imagine you need a specific metal part for your product – how do you create it? This is where custom metal fabrication comes into play. It transforms base metals into specialized parts that meet precise specifications.
Custom metal parts are crafted through a meticulous process that begins with design and ends with precision machining. First, engineers use advanced software to model a prototype that meets the client’s requirements. Following this, various fabrication techniques, such as laser cutting, CNC machining, or metal stamping, transform raw metal into the final product.
Stay with me, and I’ll be involved in some fundamental methods and tips, and you might ensure the making of top-notch custom metal parts. You might find the inspiration for your next project!
How are custom metal parts made?
Raw Material
Start by selecting the best raw materials. Metal parts can range from steel and aluminum to specialized alloys. It depends on the weight, strength, and corrosion resistance needed for the final application.
Fabrication Techniques
CNC Machining
Computer-controlled tools remove material from solid blocks to produce precise dimensions. These machines are programmed to ensure that every cut meets the specified specifications.
Laser Cutting
Laser cutting is a technique that uses a powerful laser beam to cut metal with extreme precision. This method is perfect for contours with fine details and complex shapes that are impossible to achieve using other methods.
Stamping
The metal is pressed into shape using a tool surface and die. This is a cost-effective method of producing large quantities with consistent specifications.
Metal Injection Molding
In this technique, we combine metal powder and a binder to form a “feedstock,” which we then inject into molds. We remove the binder and sinter the part into solid metal. This technique is perfect for complex shapes.
Die Casting
Die casting involves forcing molten metal under high pressure into molds. This method is ideal for intricate designs that require high accuracy.
Deburring
Deburring the parts after initial shaping removes any sharp edges and excess material. This ensures that the parts are safe for further processing.
Tumbling
Tumbling involves placing parts into a vibrating container filled with media that smoothes and polishes surfaces.
Tapping and countersinking
To create threads inside a drilled hole, we use taping. This allows the part to accept bolts or screws. Countersinking creates a conical shape around the hole, enabling the insertion of flat-head screws flush with the surface.
Bending and Forming
The metal sheet or bar can be bent and formed into certain angles or curves without affecting the thickness.
Finish
Finishing affects the part’s appearance and resistance against corrosion and wear. Option options include powder coating, painting, and plating, depending on the final use.
Hardware Insertion
We then insert fasteners such as bolts, nuts, and other hardware to create more complex structures.
How do you order custom metal parts online?
Prepare and upload your design file
Prepare a detailed design using CAD software. This file must include all specifications, such as materials, dimensions, and tolerances. Once complete, upload the file to your fabrication company’s website. Ensure your file format is compatible with the company’s systems to avoid delays.
Design and Engineering
After you upload your design, our engineers will review it to ensure manufacturability and may adjust it to optimize the production process.
Sample Production
Before starting full-scale production, manufacturers typically make a prototype or sample. This allows them to check the part for any necessary improvements or to confirm it meets all requirements. At this stage, they can still make adjustments to the design.
Mass-production
Mass production starts after the sample is approved. We will produce metal parts using CNC machining, laser cutting, and other technologies.
Quality Control
We check each part for dimensions, accuracy, and flaws. Modern measuring and testing equipment ensures your products will meet high standards.
Packaging and Logistics
Once a part passes quality control, we package it carefully to prevent damage during transit. We coordinate the logistics to ensure your order arrives on time and in perfect condition, regardless of location.
Custom Metal Parts Materials
Materials for custom metal parts can range from being aesthetically pleasing to being exceptionally durable. Here is a brief overview of the materials available:
- Chromoly: Chromium Molybdenum steel 4130 is a solid, high-carbon steel.
- 6061 Aluminium： This is a famous aluminum alloy, offering an excellent combination of strength and affordability.
- Aluminum 5052: 5052 is a flexible aluminum alloy ideal for projects requiring aluminum bending.
- 2024 Aluminium: 2024 aluminum is used for aerospace applications because of its high strength.
- 7075 Aluminium： This is the most robust aluminum available in our selection. It is suitable for demanding applications.
- AR400/AR500 steel： These highly resistant to abrasion steels are used in heavy-duty digging equipment and gun targets.
- Brass： Brass is not only beautiful but also functional. This self-lubricating material is electrically conductive, making it suitable for many applications.
- Mild Carbon Steel： Mild Carbon Steel is a cost-effective, versatile, and robust material. It can be bent and welded.
- Copper: We use copper for electrical applications, heatsinks, and decorative purposes.
- 304 & 316 Stainless Steel: Excellent corrosion resistance. Ideal for marine environments with rust problems.
- Titanium: Titanium is used extensively in high-end industries such as aerospace, automotive racing, and other sectors.
Cost considerations and optimization
Factors affecting the cost of custom metal parts
- Material Selection: Prices of different metals are affected by their availability and processing requirements.
- Design complexity: Complex designs require more advanced machining and are costlier.
- Production volume: Larger quantities lead to lower unit costs because of economies of scale.
- Manufacturing Process: The cost of the process is based on equipment and labor.
Metal Parts Manufacturing Cost Reduction Strategies
- Reduce Complexity: Minimize the number of intricate parts and waste materials.
- Select Cost-Effective Materials: Choose readily available materials that are easy to machine.
- Plan to increase production volume: Plan more significant production runs to exploit economies of scale.
- Optimize Production Processes: Reduce time and labor costs by streamlining operations.
Preflight Checklist when Submitting Design Files
Please ensure your design files comply with the following criteria before submitting them to your manufacturer.
- Accepted Formats: Ensure your files are in one of the accepted formats. For 2D designs, we accept （.dxf, .dwg, .ai, and .eps. For 3D models, please submit .step or .stp files.
- Minimum hole and cutout sizes :
- All holes and cutouts on laser-cut parts should be at least half the thickness of the material.
- All holes and cutouts on CNC-routed parts must be no smaller than 0.125 inch.
- Units and Scale: Your file must be at a 1:1 scale. For accuracy, use inch or mm measurements.
- Layer management: Place objects on the same level to simplify manufacturing.
- Clean Up: Remove all stray lines duplicate and empty text boxes.
- Contour integrity: Make sure that all shapes are closed. This is essential for accurate cutting.
- Shape Uniformity: Combine, merge, or unite all shapes to eliminate discrepancies when cutting or shaping.
- Text handling: Convert text into outlines or paths to be processed correctly.
This checklist will allow us to process your designs more quickly and accurately. It will also reduce the chances of production delays and errors.
Conclusion
To successfully produce custom metal parts, you must understand the materials and processes and prepare them carefully. Make sure your design documents and materials are correct. We can optimize your project for both quality and cost. We will guide you every step of the way to ensure that your custom components are up to specification.
Do you need a reliable sheet metal parts manufacturer? Shengen is the place to go. We specialize in sheet metal laser cutting, bending, surface finish, and CNC Machining. Reach out to Shengen Today and seek help from professionals!
FAQs:
What is the best metal for custom parts in terms of cost?
Mild steel can be the best choice in many situations. It offers strength and versatility for a lower price than specialty alloys.
How long is it usually necessary to manufacture a custom-made metal part?
The production time can vary depending on the complexity and manufacturing methods. It can range from a few hours to several weeks. The prototype may need additional time to adjust and test.
What are the most important factors that influence the quality of a metal custom part?
The choice of material, the precision of the manufacturing processes, the skill level of technicians, and the quality of machinery are all critical factors. The design of the product and its adherence to standards is also crucial.
Can custom metal components be recycled or used?
Most metal parts are recyclable or reusable. They retain their properties even after melting and reforming.
More Resources:
Properties of 4130 Chromoly – Source: Matmatch
Advantages of 6061 Aluminum – Source: Zetwerk
Recycling process for metal parts – Source: Southern Waste
How to design for manufacturability – Source: aPriori
Hey, I'm Kevin Lee
For the past 10 years, I’ve been immersed in various forms of sheet metal fabrication, sharing cool insights here from my experiences across diverse workshops.
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Kevin Lee
I have over ten years of professional experience in sheet metal fabrication, specializing in laser cutting, bending, welding, and surface treatment techniques. As the Technical Director at Shengen, I am committed to solving complex manufacturing challenges and driving innovation and quality in each project.
