After you figure out what you can do with sheet metal, you'll never approach a metal project the same again.

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Why Use Sheet Metal in your Design?

There are many manufacturing methods available, including 3D printing, CNC machining, and injection molding, among others. Why choose sheet metal? In practice, a huge percentage of the hardware, appliances, vehicles, electronics, and other products that we use every day rely on sheet metal manufacturing. Here are some reasons you should consider sheet metal when designing your next part.

Strength

It's hard to beat the strength of a metal part. Metal is of course resilient on its own, but with added bending to create flanges, you gain an incredible amount of strength and rigidity without affecting weight at all.

Figure 1. Bends in a long 16 Ga sheet metal part dramatically increase strength and rigidity without adding weight

A property called moment of inertia is used to calculate how much a piece of metal will deflect under load. Putting even a single bend in a piece of metal dramatically increases the moment of inertia of the part compared to a flat piece of metal, which in turn increases rigidity.

It's possible to create 3D metal shapes in ways besides flat cutting and bending, but that brings us to the second reason sheet metal is often an excellent choice: it is cost-effective.

Price

Figure 2. For volumetric metal parts, it's hard to beat sheet metal processes for their cost and efficiency

If you want a light, strong part, it helps to have relatively thin metal, shaped to add rigidity. Sheet metal manufacturing lends itself to exactly that type of geometry. A sheet metal "flat" is cut from a flat sheet of metal or plate, and then the material is bent to produce the desired geometry.

It's often possible to do the same with other processes like CNC machining, or 3D printing. But CNC machining requires the shape to be "hogged out" of thick, solid billet, which is both expensive and time-consuming. Similarly, 3D printing takes a significant amount of time and, depending on the technology used, does not always yield the same strength benefits of solid metal.

Speed

It has only recently made sense to use "fast" and "sheet metal" together in the same sentence. The metal fabrication industry even now is characterized by long lead-times and high costs, but a handful of companies are changing that, including OSH Cut.

Multiple services now exist that allow sheet metal parts to be quoted instantly or within hours, and lead times as short as same-day are available from OSH Cut. It's hard to overstate how important that is. Our world is increasingly characterized by speed - fast design, fast prototyping, short time to market, and rapid order fulfilment. In the history of the world, we live in an unprecedented time.

Scalability

Figure 3. Sheet metal is great for prototyping and even better for mass production

Some services like 3D printing are also known for their prototyping speed, but sheet metal has one major benefit that 3D printing doesn't: scalability.

As sexy as 3D printing is these days, virtually nothing is actually produced in volume with 3D printing. From door hinges, to appliances, to drawer glides; building trim to automotive parts; a huge percentage of the goods we consume are made out of sheet metal. The percentage made out of 3D printed parts is almost vanishingly small.

When it comes time to produce anything in volume, sheet metal is very frequently the method of choice. Sheet metal is economical to produce in volume because of its limited waste. And custom punches and dies can be produced that dramatically reduce production times and costs. So not only is sheet metal easy, fast, and cost-effective for prototyping, there is an easy path to production without changing designs or manufacturing methods.

Conclusion

We believe that we are entering the golden age of sheet metal manufacturing. Enabled by new technologies, it is now easier than ever to get sheet metal parts. Over time, rapid services like OSH Cut and others will expand their value-add offerings, making it easier and easier to order more complicated parts and get them quickly, for a reasonable price.

That will accelerate an already appealing design option: sheet metal parts are strong, inexpensive, readily available, and perfect for both prototyping mass production. And it's just going to get better from here.

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10 Benefits of Sheet Metal Fabrication

Sheet metal fabrication includes a variety of processes and can be used to create simple to complex shapes in anything from prototypes to high-volume productions. When combined with CNC machining or surface finishing processes like powder coating, it is a versatile option for any industry. Whether you choose progressive stamping, deep drawing, or laser cutting, sheet metal fabrication has numerous benefits.

Sheet Metal Fabrication Benefits

Sheet metal parts offer several benefits that make them a popular choice in various industries. The following are some of the major benefits of sheet metal fabrication that make it so appealing for many different product applications:

Here are some key advantages of using sheet metal parts:

High Strength

Metal, especially steel, offers excellent structural integrity and can withstand heavy loads and harsh environments. Sheet metal parts are ideal for automotive, construction, and industrial equipment.

Malleable

Sheet metal is easy to mold and form into various shapes, and also maintains its structural integrity when undergoing the fabrication process. Sheet metal is very popular for use in applications requiring ample malleability, such as building designs.

Durable

Sheet metal materials are also capable of holding high-pressure levels, with the added ability to resist corrosion and degradation resulting from exposure to sun, water, moisture, and corrosion in all types of environments.

Lightweight

In spite of their robustness, sheet metal components exhibit a relatively low weight when compared to alternative materials such as solid metal blocks or castings. This makes them advantageous in applications where weight reduction is crucial, such as aerospace or automotive industries, as it can contribute to improved fuel efficiency and overall performance.

Versatility in Design

Sheet metal fabrication allows for great design flexibility. Sheet metal can be easily cut, bent, and shaped into complex forms, offering designers the freedom to create parts with intricate geometries, creating customized and aesthetically pleasing components.

Cost-Effective

Raw materials, such as steel or aluminum sheets, are generally less expensive than solid blocks or castings. Additionally, sheet metal fabrication processes, such as laser cutting and CNC bending, have become more efficient and automated, reducing labor costs and increasing production rates.

High Accuracy and Precision

Sheet metal fabrication techniques have advanced significantly with the use of computer-aided design (CAD) software and computer numerical control (CNC) machines, allowing precise cutting, bending, and forming operations. This accuracy ensures consistent dimensions and tight tolerances, which is crucial in industries where precise fit and functionality are required.

Rapid Prototyping

With computer-controlled machines and efficient production setups, it is possible to quickly produce prototypes or small batches of sheet metal parts. This agility is particularly beneficial for industries that require fast product development cycles or have changing design requirements.

Short Lead Times

Sheet metal fabrication covers a range of processes. Working with a full-service contract manufacturer that handles fabrication, finishing, and assembly can drastically shorten your lead times.

Recyclable and Sustainable

Sheet metal parts, especially those made from materials like steel or aluminum, are highly recyclable. These parts can be recycled and reused to produce new sheet metal components, reducing environmental impact and promoting sustainability.

Sheet Metal Fabrication by Source International

Source International’s sheet metal fabrication capabilities can cover any project. Our full-service contract manufacturing model means we handle your project from product development all the way through shipment monitoring using our Source Information System (SIS). We will even develop a new process for you if we don’t have one that fits!

Our experienced team will work with you every step of the way to develop a product and create a process that fits your needs — all wrapped up nicely in our Product Tech Pack. This ensures you have all of the information on your product such as bill of materials, technical drawings, performance testing, sample schedules, and packaging labels.

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