Sheet Metal Fabrication Guide — Processes and Design Tips

Complete guide to sheet metal fabrication: laser cutting, bending, welding, finishing. Design for manufacturability tips.

Sheet Metal Overview

Sheet metal fabrication transforms flat sheets into finished parts through cutting, forming, and joining. One of the most cost-effective methods for enclosures, brackets, panels, and structural components.

Cutting Processes

• Laser Cutting: Fiber and CO2. Narrow kerf (0.1-0.3 mm), no tooling cost. Thickness up to 20 mm.
• Plasma Cutting: For thick plates (6-50 mm). Lower precision (±0.5 mm).
• Waterjet Cutting: No heat-affected zone. Cuts any material including composites.

Bending

• Air Bending: Most common. Flexible toolset for various angles.
• Bottom Bending: Higher tonnage, more precise angles.
• Coining: Highest precision.

Design for Sheet Metal (DFM)

• Bend Radius: Minimum = material thickness
• Hole Placement: At least 2x thickness from bend lines
• Slot Width: Minimum 1.5x material thickness
• Flange Length: Minimum 4x material thickness

Common Finishes

• Powder coating — Durable, wide color range, 60-120 μm
• Zinc plating / Galvanizing — Corrosion protection
• Anodizing (aluminum) — Wear-resistant, decorative