Within the architecture and construction industries, when we think of metal fabricators, we often think about the process of turning sheet metal into metal wall or roof panels. But many metal fabricators can do much more than just make metal panels. Sheet metal fabrication can include making everything from railing systems to steeples, finials and accents, to sunshades and custom architectural, decorative or ornamental metal work.
What to know about forming and manipulating sheet metal into building products
Photo courtesy of East Coast Metal Systems
Overview
Sheet metal fabrication is the process of turning flat sheets of aluminum or steel into a variety of metal products or components by cutting, punching, folding and assembling. Sheet metal is extremely versatile and can be cut, bent or stretched into almost any shape through the use of cutting and burning the metal.
There are a variety of sheet metal fabrication techniques that fabricators use to create the finished three-dimensional product. These can include forming, stamping, punching, rolling, laser cutting and shearing, as well as others. Each of the different techniques has a distinct purpose, and can be used in conjunction to create different shapes and components.
Oftentimes fabricators offer a variety of architectural and custom sheet metal fabrication techniques in addition to their regular metal panel fabrication services. For instance, in addition to the fabrication of composite panels, single-skin and plate panels, East Coast Metal Systems Inc. (ECMS), Triadelphia, W.Va., offers a variety of sheet metal fabrication services including rolling, welding, finishing, shearing, laser cutting, bending, cutting, punching, contouring, notching, assembly, CNC routing and radius forming.
Photo courtesy of East Coast Metal Systems
Fabrication Techniques
Here’s an overview of some of the most common sheet metal fabrication techniques:
- Cutting: Cutting is ne of the main ways to manipulate sheet metal and is often the first step in sheet metal fabrication. Common methods of cutting include:
- Laser cutting uses a powerful laser intensified with a lens or mirror to cut metal precisely, and is suitable for thin or medium gauges of sheet metal.
- Water jet cutting uses a high-pressure jet of water mixed with an abrasive substance to cut through metal.
- Plasma cutting creates an electrical channel of ionized gas, which forms a jet of hot plasma that can penetrate through thick gauges of metal.
- Shearing: Shearing uses a set of upper and lower straight-edge blades to cut flat metal into separate pieces. The blades are typically offset from each other, and the upper blade is angled to facilitate cutting.
- Stamping: A cold-forming method that transforms flat metal blanks into various shapes, using a tool and die to change the form of metal using shear pressure. In sheet metal fabrication, stamping encompasses punching, bending and embossing.
- Punching: Also known as piercing, punching creates precise holes in sheet metal using a punch and die. Punching can be used to create specific shapes and designs in finished products.
- Bending: Using a brake machine, sheet metal can be bent into V shapes, U shapes and channels to an angle of up to 120 degrees.
- Rolling: Used to create complete tubes or to roll to a specific profile, sheet metal rolling passes the metal through three rollers to shorten one face of the material and elongate the other face, causing a progressive curvature.
- Assembly: Assembly uses fastener bolts, screws and rivets to put together separate pieces of sheet metal.
- Welding: Welding joins multiple pieces of sheet metal together by applying heat to metal a section of the metal where it joins with another component. The melted metal of the two components are fused to form a solid connection. Some common welding processes include:
- MIG welding is an arc welding process where a continuous wire electrode is fed through a welding gun and into the weld pool.
- TIG welding uses an electric arc and infusible tungsten-based electrode to generate welds.
- Laser welding uses a high-powered, solid-state laser resonator to melt the metal.
- Finishing: Once the metal has been cut and formed to the project’s requirements, a surface finish is applied. Finishing can include paint and powder coatings, silk screening, or the use of sealants or other protective layers.
What Architects Need to Know
Custom fabrication allows projects to stand out and meet the design ideas and goals of the architects and owners. D.J. Hores, estimator at ECMS, explains that it’s important for architects to pursue at least a basic familiarity with common details—there can be huge labor-time and material differences associated with minor drawing changes. “The more that architects know what’s feasible—and what’s at the fringes of possible with standard fabrication techniques—the more efficient the page-to-production process will be.”
John Trifonoff, vice president at ECMS, adds, “We’ve joined forces with other members of the United States Green Building Council (USGBC) to promote the Leadership in Energy and Environmental Design (LEED) program, green building and sustainability throughout our market and the industry. This ensures an energy-efficient, better quality, environmentally responsible building for our customers.”