Fabricated metal refers to metal that is cut, bent, and assembled to create usable metal structures, parts, or products. The final fabricated metals are essential components for various industries in the modern world. Let’s learn more about the process of metal fabrication, different types of fabricated metals, and more!
What is Fabricated Metal?
Fabricated metal is metal products or structures created by metal fabrication, including cutting, bending, and assembling.
Fabrication of metal has three main phases, design, fabrication, and installation. This process adds value to raw metal, transforming it into usable products and components.
Fabricators work with various types of metal. They could be plate metal, expanded metal, and welding materials.
Common Types of Fabricated Metals
There are various fabricated metals, with each one chosen for its specific properties for particular applications. Let’s check the most common types of fabricated metals.
- Stainless steel: Resistant to corrosion and durable
- Carbon steel: Strong and versatile
- Aluminum: Lightweight and resistant to corrosion
- Copper: Excellent for electrical conductivity and heat transfer
- Brass: Suitable for decorative and low-friction applications
- Bronze: Popular in marine environments due to its corrosion resistance
- Galvanized Steel: Steel coated with zinc for more corrosion
- Tool Steel: Ideal for durable tools and machine parts
- Magnesium: Extremely lightweight
These metals are available in sheet metal, pipes, bars, or tubes, with sheet metal being the most common form.
Key Metal Fabrication Techniques
Raw metal materials need to go through a fabrication process to be usable for manufacturing and assembly. Take a look at the key techniques below!
Cutting
The cutting technique requires cutting equipment, a metal workpiece, and a work surface. This process involves removing excess ferrous or non-ferrous material from the workpiece. The unnecessary parts are trimmed away to make the resulting piece to be integrated with other components or systems.
Welding
This metal fabrication method refers to joining two metal pieces together. It requires a metal workpiece, welding equipment, shielding gas, electrodes, flux, and filler materials. These components work together to create a strong, durable bond between the metal pieces.
Bending and Forming
The bending technique uses a hydraulic press to create angled bends in metal pieces. The angles commonly include 90 degrees for right-angle joints and 180 degrees for double bends. It is often applied to straight metal pieces with specific angular shapes.
Forming refers to shaping metal to desired angles or contours. A common tool for this method is the brake press, which applies pressure to create creases or bends in metal sheets. Alternative forming methods may employ hammers and clamp bars to hold the metal in place while shaping it.
Machining
Machining is a kind of shaping process. It includes drilling, turning, and milling to remove unwanted material and create a desired form.
Punching and Stamping
Punching creates holes in metal workpieces using punch presses with specialized turrets. This technique is suitable for both light and heavy metalwork.
Stamping is similar to punching but it produces indentations. It’s used to create letters, shapes, and images on metal surfaces.
Casting
Casting relates to melting metal, and then shaping it by a premade mold cavity. There is needed post-processing to refine the cooled finish and remove imperfections.
Applications of Fabricated Metal
Fabricated metal products are highly versatile and customizable so they are used across various industries.
- In the construction industry, fabricated metal is used in metal roofing, frames, railings, beams, and columns.
- Fabricated metal is used widely for vehicle bodies and chassis in the automotive sector.
- Aerospace utilizes this metal for aircraft fuselages, wings, and engine components.
- In consumer goods, we can widely see it in appliances, furniture, and electronics.
- With industrial machinery, fabricated metal parts are essential in manufacturing, agriculture, and energy production.
Fabricated metal products can be tailored to each industry’s requirements. They could range from simple household items to complex industrial systems. They are considered indispensable in modern manufacturing and construction.
The Metal Fabrication Process
Most metal fabrication projects will go through the following main steps:
- Design
Design begins with a thorough analysis of project requirements, where fabricators can refine existing prototypes or create new designs for custom metalwork. Modern fabricators utilize software like AutoCAD to develop detailed renderings and ensure precise specifications with production.
- Prototype
During prototyping, ideas transform into physical test pieces through rapid sheet metal fabrication or 3D printing. This phase allows for thorough testing and validation of the design’s functionality. It provides an opportunity to make necessary adjustments before committing to full-scale production.
- Programming
Programming follows successful prototyping and involves setting up computer-controlled machinery. This technical phase requires precise configuration of automated systems that will handle cutting, punching, and turning operations throughout the fabrication process.
- Fabrication
This is where raw materials are transformed through various processes. Here, the fabricated metal undergoes cutting, punching, folding, welding, and machining according to the programmed specifications and design requirements.
- Finishing
Finishing enhances both the appearance and durability of fabricated items. This stage may include surface refinement, edge treatment, or the application of protective coatings like powder coating.
- Assembly
Finally, assembly brings all components together to create the finished product. This may involve welding separate pieces into a single unit or integrating electrical components.
Future Trends in Metal Fabrication
The metal fabrication industry is expected to experience significant transformation in the coming years. Take into the following trends to go ahead in the market!
- 3D printing and additive manufacturing
3D printing or additive manufacturing utilizes a CAD model or a digital 3D model to create a three-dimensional object. It deposits, joins, or solidifies materials under computer control to add layers by layers. 3D printing and additive manufacturing are challenging traditional fabricators to innovate and maintain competitiveness.
- Automation and Robotics
Automation and robotics enable fabricators to increase efficiency and reduce inconsistencies. These advances handle more projects with faster turnaround times. This shift could lead to lower costs and quicker delivery for metal fabrication.
- Sustainable Fabrication Practices
Environmental concerns will push custom metal fabricators to adopt eco-friendly materials, reduce waste, recycle, and minimize their carbon footprint.
- Digitization
Nowadays, advanced software, loT devices, and data analytics are optimizing production processes, including metal fabrication. The digital transformation will contribute to improving quality control and streamlining fabrication workflow.
Get Custom Metal Fabrication from Fischer ASIA
Fischer ASIA offers comprehensive custom metal fabrication services, specializing in high-quality metal stamping parts, assembly services, and stamping tools.
Our metal stamping process focuses on achieving high output rates with zero defects. We ensure top-notch quality through meticulous process design and evaluation.
The assembly services cover from product development support to finished product assembly and packaging design. Fischer ASIA manages the entire production chain, including supplier coordination for purchased parts.
With years of expertise in tool design and manufacturing, Fischer ASIA produces cutting-edge stamping and deep-drawing tools. Our technological capabilities allow for the creation of smart, efficient tooling solutions.
Partner with Fischer ASIA for your fabricated metal needs and benefit from their comprehensive service offering, commitment to quality, and innovative approach!
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