About Metal Fabrication

Understanding Metal Fabrication


Metal fabrication is the process of transforming raw or semi-finished metals into finished parts or structures through cutting, bending, welding, and assembling. It plays a critical role in industries like food service, medical, electronics, and construction by producing everything from custom components to full-scale equipment.

Common Metals Used in Fabrication

When it comes to custom metal fabrication, choosing the right material is essential. Each type of metal has its own strengths, making it more suitable for certain applications. Below is a quick guide to some of the most commonly used metals in fabrication and what makes them unique:

Aluminum

Aluminum is lightweight but strong, making it a great choice when weight matters—like in the aerospace or automotive industries. It's also resistant to rust and works well in cold environments. On top of that, aluminum conducts heat and electricity efficiently, which adds to its versatility.

Steel

Steel is one of the most widely used metals thanks to its strength and durability. There are different types of steel, including carbon steel and stainless steel. Carbon steel is strong and cost-effective, while stainless steel is known for resisting corrosion and having a sleek, polished look. It’s commonly used in food service, medical tools, and construction because it’s easy to clean and stands up to tough conditions.

Copper

Copper has a distinctive reddish color and offers excellent electrical and heat conductivity. It’s also flexible and easy to shape. Copper is often used in wiring, plumbing, electronics, and even decorative pieces. Its natural resistance to corrosion makes it a smart choice for outdoor or marine applications.

Iron

Iron is a tough and dependable material, especially for handling heavy loads, high heat, and mechanical stress. It’s widely used in construction and equipment manufacturing. Because iron is readily available, it’s also an affordable option for many projects.

Magnesium

Magnesium is the lightest structural metal used in fabrication, yet it’s still strong. It’s ideal for parts that need to be both lightweight and heat-resistant, such as components in cars, airplanes, or high-speed machinery. Magnesium is also safe for use in medical devices because it’s biocompatible (works well with the human body).

Material Forms

These metals typically come in different shapes and sizes to suit the needs of each project such as sheets, bars, plates, and tubes. The form used depends on the product design and how the metal will be shaped, cut, or welded during fabrication.

Understanding Metal Fabrication Processes

Metal fabrication is the process of turning raw metal into finished parts or products. It involves a variety of techniques each with unique tools and purposes to cut, shape, or join metal into useful components used in everything from cleanrooms to kitchens. Below is an overview of the most common fabrication processes, explained simply:

1. Cutting

Cutting is one of the most basic and essential fabrication techniques. It involves slicing large pieces of metal into smaller sections. This step is often the first in many projects.

Common cutting methods include:

  • Laser Cutting – For precise, clean cuts
  • Waterjet Cutting – Uses high-pressure water, ideal for heat-sensitive materials
  • Plasma Cutting – Fast and effective for thicker metals
  • Shearing, Sawing, Die Cutting, CNC Cutting – Used depending on the metal and shape needed

Benefits: High precision, repeatable results, and good for custom or mass production.

2. Forming & Bending

Forming (also called bending) changes the shape of metal without cutting or removing any material. This is done using press brakes, rollers, or even hand tools depending on the size and complexity of the job.

Used for: Making parts like brackets, enclosures, panels, and tubing.

Benefits: Allows for complex shapes and curves with minimal waste.

3. Welding

Welding joins two or more pieces of metal using heat and sometimes pressure. It’s a key process for creating strong, long-lasting joints in fabricated parts.

Common types of welding include:

  • MIG (Metal Inert Gas) Welding
  • TIG (Tungsten Inert Gas) Welding
  • Stick Welding (SMAW)
  • Flux-Core and Submerged Arc Welding

Benefits: Durable bonds, minimal waste, and applicable across many industries, including food service and medical equipment.

4. Stamping

Stamping uses specially shaped dies to press metal into a specific 3D shape like molds. It’s often used in high-volume production, such as making panels or frames.

Used for: Automotive parts, electrical enclosures, appliance components.

Benefits: Fast, accurate, and cost-effective for mass production.

5. Machining

Machining removes material from a piece of metal to create a specific shape. Modern machining is often done with CNC (Computer Numerical Control) equipment, which automates the process for accuracy and repeatability.

Processes include:

  • Milling – Cutting and shaping flat or curved surfaces
  • Turning – Rotating the metal while cutting (like on a lathe)
  • Drilling – Creating holes

Benefits: Tight tolerances, excellent surface finishes, ideal for detailed parts.

Common Metal Forms

Metals used in these fabrication processes typically come in standard stock forms like:

  • Sheets
  • Bars
  • Plates
  • Tubes

Fabricators choose the best form based on the part’s design and function.