Cast Plate
Knowing how a metal fabrication process like welding or machining is done is not the same thing as knowing how to do that process well.
If it were, then metal fabricators wouldn’t have bins full of broken mill ends and other bits accumulating for recycling. Sheet metal fabrication shops wouldn’t need replacement torch heads as frequently, and the overhead for material purchases would be significantly lower.
Metal fabrication tips and tricks are the little things that make completing a process either easier or substantially improve the quality of the end result.
Oftentimes, they accomplish both. A worker who isn’t exhausting themselves trying to make awkward positioning or uneven surfaces work is free to do the best job possible.
Metal Fabrication Tips and Tricks for Beginners and Pros
Frequently, the difference between a job done well, one barely completed, and one that takes two or more tries is a little extra effort in setting things up before getting started. This can also be more than just a time and money savings.
The equipment used in metal fabrication work can be dangerous if used incorrectly. The finished product often is used in difficult environments, and a finished product that fails can cause hazards.
Taking a little extra time to think through what metal fabrication tips and tricks to use can prevent injury and save time and money.
1. Work Through the Process Before Starting
The most basic and important metal fabrication tip is to work through the actual fabrication process completely before starting.
It is not uncommon in machine shops 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, but it is nearly impossible to machine in real life.
Sheet metal fabrication isn’t subject to the same extremes of impossibility. Still, shop drawings requiring 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 action plan 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 needed adjustments. It is well worth the time to ensure these devices are in the inventory if a need for them is discovered during planning.
These can vastly speed up production times in large jobs where many pieces need to be assembled quickly, especially in sheet metal fabrication.
4. Never Trust the Mill’s Edge
A common error in metal fabrication is to begin measuring dimensions from the existing edge when confronted with a new, clean piece of metal directly from the foundry.
This is a mistake because unless one has taken the time to employ a precision metal cutting service, these edges are never straight. As the project progresses, everything is slightly off.
Metal fabricators should always take the time to make a true edge to measure their dimensions off of, whether they cut it or 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. This sawing service is worth far more than its price on large jobs.
On small jobs, taking the time to cut true edges before starting substantially enhances the precision of the work and the quality of the final workpiece.
5. Guides Make a Difference
Welders are excessively proud of their ability to draw straight lines freehand. Doing so repeatedly is a vital skill for welders and is especially 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 in the ease and precision of the workpiece, especially in sheet metal fabrication. 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 freehand.
These are all common-sense measures. However, they are often overlooked in the rush to complete the job.
While taking the time to think things through, have a plan, and get the needed equipment can seem like a delay, it makes all the difference in the final quality of the piece.
It is the basics that are most often overlooked by both professionals and hobbyists. At the most basic level is buying metal materials and raw materials from a supplier you can trust.
Buy Certified High-Quality Metals for Industrial Solutions | ||
New Aluminum | New Steel | New Stainless Steel |
 |  |  |
| Reliable supply: Consistent, certified aluminum stock you can trust. High-quality material: Superior-grade aluminum for precision needs. Custom cuts: Accurate cuts down to thousandths of an inch. | Durability and strength: Reliable for projects needing long-lasting, tough materials. Cost-effective: Quality steel that offers strength without breaking the bank. Custom cutting: Precise cuts tailored to exact needs with top-tier cutting tools. | Sustainability: Highly eco-friendly as the most recyclable metal on earth. High durability: Resistant to corrosion and wear, ensuring long-lasting performance. Custom precision cuts: Tailored to your specifications with quick, accurate results. |
Additional Tips for Sheet Metal Fabrication
When working with sheet metal, it’s important to consider the material thickness and bend radius to avoid cracking or warping the metal. Press brake machines are ideal for creating precise bends, even in complex geometries.
Ensure you’re using the right tools and techniques, like laser cutting for complex shapes or intricate details, to achieve the best results.
Proper protective gear is essential when working with softer metals or when performing plasma cutting to ensure safety and maintain the integrity of the finished product.
By following these tips and sourcing your metal materials from trusted suppliers, you can reduce labor costs and produce high-quality finished products with tight tolerances and complex details.
Finding an Aluminum and Metal Supplier You Can Count On
In addition to providing process ready metal stock for your fabrication project metal sawing services can provide a reliable source of exactly the hard metal alloys that you need.
Industrial Metal Service is a company with decades of experience in metal recycling and sales. We have direct contact with aluminum manufacturers and can provide you with metals from 6061 aluminum, cast aluminum tooling plates, stainless steels and nickel super alloys to meet your needs.