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Sheet Metal Design & Fabrication Guide for Manufacturing
Sheet metal fabrication is one of the most cost-effective manufacturing methods for enclosures, brackets, and structural components. This guide covers key design and fabrication considerations.
Common Sheet Metal Materials
| Material | Thickness Range | Cost/kg | Typical Use |
|---|
| Cold Rolled Steel (CRS) | 0.5-6.0 mm | ¥5-10 | Enclosures, brackets, chassis |
| Galvanized Steel (SGCC) | 0.5-4.0 mm | ¥6-12 | Outdoor, corrosion-resistant |
| Stainless Steel 304 | 0.5-6.0 mm | ¥25-45 | Food, medical, marine |
| Aluminum 5052/6061 | 0.8-6.0 mm | ¥25-40 | Lightweight, corrosion-resistant |
Design Guidelines
- Minimum bend radius: 1x material thickness (aluminum: 1.5-2x)
- Hole distance from edge: ≥ 2x material thickness
- Slot width: ≥ 1.5x material thickness
- Flange height: ≥ 3x material thickness
- Uniform bend direction reduces tooling changes
Fabrication Tolerances
- Laser/plasma cutting: ±0.1-0.3 mm
- Bending angles: ±0.5-1°
- Formed dimensions: ±0.2-0.5 mm (first piece)
- Welded assemblies: ±0.5-1.5 mm
Finishing Options
- Powder coating: most common, wide color range
- Zinc plating: cost-effective corrosion protection
- Anodizing: aluminum only, decorative + protective
- Brushed + clear coat: aesthetic, premium
Cost Drivers
Laser cutting: ¥1-5 per cut meter. Bending: ¥3-15 per bend. Welding: ¥50-150/hour. Finishing: ¥8-25/kg. Setup charges: ¥200-1,000 per job.
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