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Metal fabrication refers to the process of creating products or structures by cutting, bending, and assembling various metal materials. This is typically a multi-step process that starts with raw materials such as metal sheets, expanded metal, welding wires and rods, cast metal, and more. These materials are then shaped and assembled into the final product.
The Metal Fabrication Process
The fabrication process generally involves three primary stages:
1. **Design** - This is where a metal fabrication shop collaborates with you to create detailed drawings and plans. These plans outline the precise measurements and specifications necessary for your project.
2. **Fabrication** - This stage involves using machinery to cut, bend, shape, and assemble the metal components into the final product. Advanced technologies like CNC machines and laser cutters are often used to ensure precision and efficiency.
3. **Installation** - During this phase, all the various components of the metal project are brought together, either partially or fully installed. This stage requires careful coordination to ensure everything fits correctly.
Here are some common custom metal fabrication processes:
- Casting
- Forging
- Milling
- Drilling
- Turning
- Bending
- Drawing
- Punching
- Welding
Types of Metal Fabrication
Industrial Metal Fabrication
Industrial metal fabrication focuses on integrating parts or assemblies into larger industrial products. This often involves working with sheets or plates of metal. Metal fabrication is used across a broad spectrum of industries, including aerospace, energy, material handling, automotive, and more. The products created for industrial purposes are usually produced in large quantities and sizes, such as large tanks, silos, and heavy machine parts.
Structural Metal Fabrication
As the name suggests, structural metal fabrication involves creating metal parts that are used in construction and other commercial, industrial, and residential projects. I-beams are a classic example of a common structural part. Steel is the most popular choice due to its excellent strength-to-weight ratio. Other metal parts frequently fabricated for structural purposes include stairs, walkways, towers, platforms, trusses, girders, and beams.
Commercial Metal Fabrication
Take a look around any commercial facility—a restaurant, retail store, or public space—and you'll likely see metal products that have been fabricated for commercial use. The two main categories of commercial metal fabrication are decorative and ornamental. Examples include awnings, shelves, guardrails, sinks, appliances, and conveyors. Compared to industrial and structural fabrication, commercial products tend to be smaller and more precise in their purpose.
Custom Metal Fabrication
The possibilities of metal fabrication are vast, and often projects require custom designs to meet unique needs. This is where a specialized metal fabrication shop can help. These shops often offer custom design services using CAD tools to conceptualize and specify design plans. Once the product is fully designed, the manufacturing process begins, utilizing methods tailored to the specific project, function, materials, and other factors.
Learn more about our fabrication solutions.
Metal Fabrication Glossary
- **ARC Welding** - Joining metal by using electricity to melt metal, creating a strong bond once cooled.
- **Assembling** - The process of binding, bending, and welding materials into their desired form.
- **Base Metal** - The original metal that is to be welded, cut, or manipulated.
- **Bending** - The process of shaping metal sheets into desired forms using hammers or press brakes.
- **Blanking** - Cutting out a part of sheet metal and discarding the excess material around it.
- **Brinell Test** - A method to measure the hardness of steel by pressing a hard steel ball into the material and measuring the mark left behind.
- **CNC Cutter** - An automated machine tool that uses computer programming for precise cutting commands.
- **Cutting Torches** - Tools used to cut large sections of sheet metal and other materials with minimal effort.
- **Fab Shops** - Short for metal fabrication shop.
- **Hydroforming** - A technique that uses high-pressure fluid to shape metals like steel, stainless steel, aluminum, copper, and brass.
- **Laser Cutting** - Using concentrated beams of light to pierce and cut through materials via extreme heat. Fiber-optic lasers are increasingly popular.
- **Metal Fabrication** - Building metal structures through cutting, bending, and assembly.
- **Metal Punching** - Punching holes or shapes into metal using fabrication equipment.
- **Milling** - Removing material from metal using rotary cutters.
- **Plasma Cutting** - Cutting materials, especially sheet metal, using hot plasma.
- **Press Brakes** - Machines used to bend sheet metal into different forms using various die designs.
- **Robotic Welding** - Welding performed by programmed technology and sophisticated equipment, ideal for high-volume welding tasks.
- **Roll Forming** - Bending metal to form new shapes by passing it through rolls.
- **Sand Blasting** - Removing unwanted coatings and coverings from surfaces using abrasive blasting.
- **Weld Pass** - The single progression of a weld along a joint or substrate.
- **Yield Point** - The point at which a metal or material permanently deforms.
Interesting Facts About Metal Fabrication
Here are some intriguing facts about welding and metal fabrication.
Welding and Earth's Atmosphere
Did you know that outside of Earth’s atmosphere, two pieces of uncoated metal will naturally fuse upon contact without the need for welding? This happens because our atmosphere contains a layer of oxidized material that prevents metals from bonding naturally. While this might sound like a futuristic problem, it also means that if we ever lose our atmosphere, welding could become obsolete. Of course, if this were to happen, we'd face far greater challenges than just welding!
Welding is Everywhere
It’s estimated that over half of the products in the United States require some form of welding before entering the market. From bridges and ships to cars and computers, welding plays a crucial role. Interestingly, the first industrial robot was used for spot welding in 1961 by General Motors. Back then, these robots were massive and cumbersome compared to today’s advanced robotic welders.
Impressive Welding Records
Some welding records are truly astonishing. For instance, the deepest underwater dry weld was performed at 1,075 feet below the surface. On the flip side, the deepest wet weld reached an incredible depth of 2,000 feet! And according to the Guinness Book of World Records, the largest welding lesson involved 275 participants.
A Long History of Welding
While welding might seem like a modern practice, it actually dates back thousands of years. Archaeological evidence suggests that ancient civilizations like the Egyptians were fusing metals as early as 3,500 B.C., long before we understood the science behind atmospheric effects on welding. Their ingenuity laid the foundation for modern metal fabrication.
High-Quality Welding Services at TYMETAL
At TYMETAL, we’re proud to be the go-to metal fabrication shop for the Saratoga Springs area. Our skilled welders and advanced robotic welding services set us apart. Robotic welding allows us to handle large volumes of material quickly and precisely, ensuring consistent quality across every project. If you're interested in learning more, check out our recent blog post on robotic welding.
Contact Us Today
TYMETAL offers a comprehensive suite of services, including plasma cutting, CNC machining, bending, laser cutting, and more. We’re here to turn your ideas into reality. Partner with us, and we’ll bring our expertise, experience, and technology to find the most efficient and cost-effective solution for your project.
Ready to learn more? Schedule a consultation today! We’d love to hear from you.
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