Metal fabrication involves turning raw metal into useful parts or structures through cutting, bending, welding, and assembling. It plays a key role in the manufacturing, construction, and engineering industries.

The process includes several steps, each contributing to the final product. Whether making small, detailed pieces or large structural elements, metal fabrication is essential for creating high-quality, functional products from metal.

You can cut aluminum sheet metal using hand tools or machines. For small projects, tools like tin snips or a jigsaw work well. For clean, fast cuts on large jobs, use a shear, laser cutter, or CNC machine. The right method depends on your sheet thickness, volume, and accuracy needs. Always secure the sheet and wear safety gear before cutting.

Copper fabrication means turning raw copper into finished parts. It involves several steps, including cutting, bending, forming, welding, and assembling.

Fabricators start with copper sheets, rods, or tubes. They then use machines or tools to make parts for various uses. Copper parts are common in electronics, heating systems, and architectural components.

Brass fabrication means shaping brass into different parts or products through specific methods. Common methods include cutting, forming, and welding. Fabricators use these processes to turn raw brass materials into useful items or components.

Low-volume production refers to the manufacturing of a limited number of units, typically ranging from a few tens to a few thousand. This method allows businesses to produce products on a smaller scale but with the same quality as mass production. It’s often used for prototypes, product tests, or limited-run items. Companies can use this approach to perfect their designs before committing to mass production.

Copper is known for its excellent electrical conductivity, making it perfect for electrical wiring. Brass, an alloy of copper and zinc, offers great machinability and is commonly used in plumbing fixtures. Bronze, an alloy of copper and tin, is renowned for its durability and resistance to corrosion, making it ideal for maritime applications.

A tap is a tool used to cut threads inside a hole. It works by removing material and shaping the internal wall so a screw or bolt can fit. Taps come in many shapes and sizes. Some are made for hand use, while others are used on machines. They are designed to match specific thread sizes and standards, like metric or UNC.

A tapped hole is prepared to have a threaded inner surface. A simple drilled hole is transformed into a tapped one, ready to receive a screw or bolt. This technique is essential for creating joints that are both strong and detachable. It allows easy assembly and disassembly.

Thread galling happens when the bolt and nut threads stick together during tightening. The pressure and friction between the surfaces cause the metal to tear or seize. This is most common with stainless steel, aluminum, and titanium. These materials have sticky properties and tend to weld under pressure without lubrication.

Metal galling is when two metal surfaces, typically under load and in motion relative to one another, adhere to each other at points of contact. This unintended adhesion can tear the metal surface when the parts are separated or moved, which compromises the integrity and functionality of the components.

A blind hole is a hole drilled, milled, or bored into a material that doesn’t penetrate through to the other side. Unlike through holes, blind holes have a defined depth and a bottom surface. They are commonly used in applications where a fastener or component needs to sit flush or be hidden within the material.

Springback refers to a material’s tendency to revert to its original shape after being bent. When force bends the metal, it deforms both elastically and plastically. After the force is removed, the elastic part tries to recover. This rebound is what we call springback.

Electrical Discharge Machining (Sinker EDM) is a metal removal process that uses electrical sparks to remove material from the workpiece. This process involves submerging the electrode and the workpiece in dielectric fluid. High-frequency electrical pulses then erode and melt the surface of the piece.

Titanium is lighter, stronger, and more corrosion-resistant than stainless steel. It’s ideal for aerospace, medical implants, and high-performance applications. Stainless steel, on the other hand, is more affordable, easier to machine, and better for everyday use, such as kitchen appliances or construction.

For most projects, aluminum is the better choice due to its lower cost, easier machinability, and lighter weight. However, titanium excels in high-strength applications requiring corrosion resistance and biocompatibility. Your specific project requirements will determine which metal is best suited for your needs.

Laser marking is a process that uses a focused laser beam to create marks on a material’s surface. The laser changes the material’s color or texture, leaving text, logos, or codes behind. It’s fast, clean, and doesn’t require inks or chemicals. This makes it ideal for industries that need durable, high-quality markings. Laser marking is non-contact, meaning the material has no physical wear. The marks are also resistant to fading, scratching, and heat.