Sheet Metal: Types, Applications, and Fabrication Techniques

One of the reasons metals such as steel, aluminum and stainless steel are so widely used is the range of shapes and configurations you can buy them in. From beams to tubes, there is usually something to suit a particular task.

Sheet metal however, is probably the most versatile of them all. In this article, we discuss the different types, the industry applications of it, and how it’s made into finished products.

Introduction to Sheet Metal: Definitions and Overview

Sheet metal is measured by its gauge (thickness), and ranges from 0.5mm to 6mm. In general, sheet metal thicker than 6mm would be plate. It has been made for decades now, in almost every metal commonly used to fabricate parts, including mild steel, stainless steel, aluminum, copper, brass, titanium, zinc and more.

As well as plain metal sheets, coated sheets are also available, these are mild steel sheets, typically with a zinc-based coating. Galvanized sheet provides good protection against corrosion, and Zintec is preferred when the parts are cut with a laser cutting machine.

Applications of Sheet Metal: Industries and Real-World Uses

It would be hard to find an industry involving the use of fabricated metal components that does not utilize sheet metal in some way. Thanks to its wide range of applications and secondary processing options, it can be made into all sorts of products.

Enclosures and Coverings

All sorts of industrial and domestic products use sheet metal, such as toolboxes, washing machines, conveying systems and CNC machines. Sheet metal is perfect for enclosing wiring, framework and mechanical components for both safety and aesthetics purposes.

Further to that, in conjunction with laser cutting or even traditional techniques, control panels with cut-outs for screens, buttons and gauges can easily be made in sheet metal, offering a strong but sealed unit.

Bracketry and Supporting Members

Whilst it may seem weak in its natural state, sheet metal can be incredibly strong when bent and/or welded into shapes. Commercially available products such as Unistrut and Catnic Lintels all start out as sheets of steel.

Smaller components, too, are commonly made from sheet metal, such as mounts for motors or radiators in cars, machines and AC units. In many cases, the outer sheet metal casing of a product serves as the framework to support the working load.

Fabrication Techniques for Sheet Metal: Processes and Tools

One of the biggest advantages of sheet metal is its versatility in processing; there are dozens of different techniques and tools dedicated to manipulating, cutting and joining it.

Sheet Metal Fabrication Processes

• Shearing – shearing with a guillotine is a traditional method of prepping sheet metal parts, and is still often used for simple components. It is also used at the end stage of making sheet metal, cutting it into the standardised sheet sizes.
• Laser cutting – possibly the most important innovation in metal fabrication of the last century, laser cutting gives the ability to quickly cut sheet into complex shaped parts with incredible accuracy.
• Bending – bending or folding via either a press brake or folding machine, is another invaluable process, allowing 3 dimensional shapes to be made, increasing the strength and functionality of sheet metal components.
• Thread inserts – to aid bolting sheet metal parts together and to other parts, adding threads is vital. This can be done by a few methods, including sheet-nuts (or riv-nuts), thermal drilling or stud-welding.
• Welding – most types of welding are used in making sheet metal parts, the most common being MIG, TIG and spot welding, the latter being the fastest and most efficient.

Sheet Metal Tools

• Traditional sheet metal tools – Many fabrication shops still use the traditional sheet metal tools, as they offer great flexibility, but require experienced fabricators. These tools include: guillotines, notching machines, rollers, punches, drills and welding equipment.
• Laser cutting – Much of the sheet metal used in modern times is processed via laser cutting machines, which use high-power laser beams to cut through the sheet, with incredible accuracy and speed, allowing for complex shapes to be made at relatively low prices.
• Press Brake – Being able to bend sheet metal with great accuracy and speed is vital to making the dimensionally accurate components modern industry requires. Many press-brakes are now CNC controlled, having automated back-stops and top dies, allowing for very fast complex bend sequences to be made.
• Welding – being able to join cut, drilled or bent sheet metal parts is invaluable, modern welding achieves this with minimal heat distortion or spatter.

Best Practices in Sheet Metal Working: Tips for Quality and Efficiency

Being able to understand the complexities of how sheet metal parts are made is vital to designing efficient and satisfactory products using them. This includes manufacturability, tolerancing and more.

Allow space between bends and features

Press brake tooling is well adapted to complex parts, but there are still hard limits of how close bends can be, and how close holes and other features can be to bends.

Putting bends too close can make the part impossible to make, and putting holes too close can cause stretching of the hole when pressing. It’s a good idea to check with your fabricator before finalising designs.

Use a coated metal

Zintec sheet is not much more expensive than normal mild steel, but it offers an extra layer of protection from corrosion. It can still be powder coated as normal after fabrication.

Galvanized sheet is perfect for parts that need no painting but need some protection from the elements. If corrosion resistance is the ultimate goal, consider stainless steel instead.

Consider a thinner material.

With some simple additional features, like stiffening bends, flanges or welded supports, sheet metal parts can be strong, yet made of thin material. This can help with material costs upfront, but also lower weight and transport costs further down the line.

Get Sheet Metal From Metals Supermarket

Whether you need brass, aluminum, copper, stainless steel or plain old mild steel, Metals Supermarkets has what you need, with a nationwide cutting service to boot. Find your nearest store here, or start browsing our sheet metal stocks now.