Sheet Metal Manufacturing Blog

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Design and manufacturing of metal enclosures.

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Latest Manufacturing Articles

In-depth guides to help you make better design and manufacturing decisions.

4130 Tubing and 4140 Machined Steel Parts

4140 vs. 4130 Steel: Machining, Welding, and Selection

The main difference between 4140 and 4130 steel is their carbon content. 4140 contains 0.40% carbon, providing higher strength and deeper hardenability. 4130 contains 0.30% carbon, offering superior weldability and toughness. Both are chromium-molybdenum (chromoly) alloys, but they serve completely different manufacturing needs.

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Why Surface Condition Matters Before Coating or Bonding

Laser Texturing for Metals: Prep, DFM & Cost Control

Laser texturing is a non-contact surface preparation process that uses a focused laser beam to selectively ablate material. It creates highly precise micro-patterns to improve a part’s functional properties, such as coating adhesion, wettability, and wear resistance.

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Why Electro Galvanized Steel Is Chosen for Precision Parts

Electro-Galvanized Steel: Fabrication & Selection Guide

Electro-galvanized (EG) steel is produced by electrolytic deposition, creating a thin, uniform zinc layer on the surface of cold-rolled steel. In manufacturing, it is primarily selected when a project requires a combination of aesthetic finish, precise dimensional control, and moderate corrosion resistance. Unlike hot-dip galvanized steel, which is often used

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Quick Process Selection Guide for Punching vs Laser Cutting in Manufacturing Decisions

Punching vs Laser Cutting: Cost, Speed and DFM Trade-Offs

Punching excels in high-volume runs with repetitive shapes, standard holes, or formed features like louvers, offering unmatched speed and lower per-part costs. Laser cutting is superior for low-to-medium volumes, tight-tolerance geometries, and intricate designs, eliminating tooling costs and ensuring flawless edge quality across varying material thicknesses.

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Why Tight Internal Fillets Get Expensive

Fillet Machining: What Drives Cost and Part Quality

In CAD software, adding a fillet is as easy as selecting an edge and typing a number. On the shop floor, that same click can double the machining time, force the use of fragile micro-tooling, and send the part cost through the roof. Fillets—the rounded transitions between two surfaces—are a

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Setup Cost vs Unit Cost

Setup Cost vs Unit Cost in Sheet Metal Manufacturing

Every project starts with a question: why does the first piece cost so much more than the rest? This is a common frustration in sheet metal fabrication. The reason lies in setup cost—time, labor, and tooling before production begins. While small runs bear the full weight of setup expenses, larger

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