1. Work Through the Process Before Starting

The most basic and most important metal fabrication tip is to work through the actual production process completely before getting started. In machine shops it is not uncommon to receive technical drawings that are nearly impossible to machine as they are initially presented. A tube that makes multiple right angle turns is very useful on paper. However, it is nearly impossible to machine in real life. Welding fabrication isn’t subject to the same extremes of impossibility, but shop drawings that would require the welder to complete a highly technical weld while simultaneously doing a handstand have been known to happen. While technically possible to perform, it isn’t practically feasible.

Developing a clear plan of action for metal fabrication before starting will identify any potential pitfalls before metal materials and equipment have been expended. If there are none, then a clear plan of action will enable completion with the best quality of work.

2. Use the Right Materials

That there are differences between metals like aluminum, steel, and stainless steel are widely known. Even professionals may be unaware of the differences between different alloys of aluminum and other metals. There is a high degree of difference between 6061 aluminum vs 6063, and even wider degree of difference between 5000 series aluminum and cast aluminum plate in the 7000 series. The differences between different grades of steel and stainless steel are subtler, but can still be consequential. Knowing what the specifications call for and using the material will save time, money, and frustration. It is always worth the effort to ensure that you’re using metal with a mill test certificate or verified aluminums.

3. Have the Right Tools

Some tools are no-brainers. Machinists need mill ends and bits, not to mention CNC machines and lathes. Welders need the welder of course and all manner of grinders and cutting devices. Clamps, anchors, slides, magnetic welding angles, and all manner of anchoring tools are often overlooked. These devices hold workpieces in place, and free up hands to make extra needed adjustments. It is well worth the time if a need for these devices is discovered during planning to make sure they’re in the inventory. In large jobs where a lot of pieces need to be assembled quickly these can vastly speed up production times.

4. Never Trust the Mill’s Edge

A common error in fabrication is when confronted with a new clean piece of metal direct from the foundry is to begin measuring dimensions from the existing edge. This is a mistake, because unless one has taken the time to employ a precision metal cutting service these edges are never straight. This causes everything to be slightly off as the project progresses. Metal fabricators should always take the time to make a true edge to measure their dimensions off of, whether they cut it or they mill it. Companies that specialize in accurate metal sawing can make a huge difference here, as they can deliver process ready metal directly to metal fabricators. On large jobs this sawing service is worth far more than its price. On small jobs taking the time to cut true edges before starting enhances the precision of work, and the quality of the final workpiece substantially.

5. Guides Make a Difference

Welders are excessively proud of being able to draw straight lines freehand. Doing so over and over is vital skill for welders, and important when in the field erecting structures or assembling a pipeline through a wilderness. When you’re fabricating something in a shop, guides make a difference on ease and precision of the workpiece. Even if these guides are as simple as a piece of angle iron tack welded in place. If the quality of the final work isn’t inducement enough to use guides, then a piece of plasma cut metal that used a guide requires a whole lot less grinding than one cut free hand.