The Ultimate Guide to Sheet Metal Fabrication

What is Sheet Metal Fabrication?

Sheet metal fabrication is the process of forming metal sheets into structures or parts through various fabrication techniques such as cutting, bending, and assembling. The sheet metal is usually less than 6 mm thick and is formed into various shapes and sizes. Common products that are made through sheet metal fabrication include metal roofs, car bodies, HVAC ductwork, and electrical cabinets.


Sheet Metal Fabrication Uses

Sheet metal fabrication is used in a wide range of industries and applications. Some common uses of sheet metal fabrication include:

Sheet metal is commonly used in the construction industry for roofing, siding, and flashing.
Sheet metal is used to make car bodies, as well as various parts such as engine covers and exhaust systems.
Sheet metal is used to make electrical cabinets and other components used in electrical systems.
Medical Equipment
Sheet metal used to fabricate various medical equipment such as X-ray machines, MRI equipment, and more.
Kitchen equipment
Sheet metal is used to manufacture various kitchen equipment such as Ovens, dishwashers, and many more.
Sheet metal is used in the aerospace industry for making parts of aircraft, satellites, and missiles.

Other than the example mentioned above, sheet metal fabrication can be used to manufacture many other products in various other industries as well.

How to Fabricate Sheet Metal?​

Sheet metal fabrication typically involves several steps, including:

  • Cutting: The sheet metal is cut to the desired size and shape using various cutting methods such as shearing, laser cutting, and water jet cutting.
  • Bending: The sheet metal is bent into the desired shape using a press brake or other bending tools.
  • Assembling: The various parts of the sheet metal are assembled together using welding, riveting, or other fastening methods.
  • Finishing: After the sheet metal is fabricated, it goes through a finishing process such as polishing, painting, or powder coating to improve its appearance and protect it from corrosion.
  • Inspection: Quality check before delivering.

The specific fabrication techniques used will depend on the product being made, the materials being used, and the desired level of precision. Many sheet metal fabrication Malaysia shops use computer-aided design (CAD) and computer-aided manufacturing (CAM) software to assist with the design and production of the parts.


It’s possible that some additional processes can be added depending on the final product and the complexity of the design, these can include punching, stamping, spinning, deep drawing and more.


What Are The Common Metals Used in Sheet Metal Fabrication?

A wide variety of metals can be used in sheet metal fabrication, but some of the most common include:

  • Steel: Steel is one of the most widely used metals in sheet metal fabrication. It’s durable, strong, and relatively inexpensive, making it a popular choice for many applications.
  • Aluminum: Aluminum is lightweight, corrosion-resistant, and easy to work with. It’s often used in aerospace and automotive applications, as well as in the construction industry.
  • Stainless steel: Stainless steel is a popular choice for applications that require corrosion resistance, as it does not rust or corrode as easily as regular steel. It’s often used in the food industry, medical equipment, and marine applications.
sheet metal fabricaation
  • Copper: Copper is a good electrical conductor and is resistant to corrosion. It’s often used in the electrical industry, particularly for the production of electrical wiring.
  • Brass: Brass is an alloy of copper and zinc. It’s strong and has a good corrosion resistance. It’s often used for decorative purposes and in the production of musical instruments.
  • Galvanized Steel: It’s steel that is covered with zinc to prevent rusting, often used in applications such as roofing, ductwork, and fence.
  • Titanium: is extremely light weight and has a high strength-to-weight ratio, making it popular in aerospace applications, it’s also resistant to corrosion, and non-toxic, making it a good choice for biomedical applications.

Additionally, there are many other metals and alloys that can be used in sheet metal fabrication as well. The selection of the metal to be used depends on the requirements of the final product such as strength, corrosion resistance, weight, and cost.


Surface Finish Selection for Sheet Metal Fabrication

The surface finish of sheet metal parts is an important consideration in sheet metal fabrication, as it can affect the aesthetic appeal, functionality, and lifespan of the product. Some of the most common surface finishes for sheet metal include:

  • Bare metal: This is the natural finish of the metal, and is often used for parts that will be painted or powder coated later on.
  • Painting: The surface of the metal is painted, which can provide a wide range of colors and can protect the metal from corrosion.
  • Powder coating: The surface of the metal is coated with a dry powder which is then baked on to create a hard finish. This method can provide a wide range of colors and can be more durable than paint.
  • Anodizing: Anodizing is an electrolytic process that forms an oxide film on the surface of the metal. This film can be dyed in a range of colors and can improve corrosion resistance.
  • Plating: The metal surface is covered with a thin layer of another metal, such as chrome, to improve appearance and corrosion resistance.
  • Polishing: The surface is polished to a high shine to improve the aesthetic appeal and corrosion resistance.
  • Sandblasting: The surface is blasted with an abrasive material to create a uniform and fine-grained surface, it’s often used to provide a rough texture or to remove surface contaminants.
  • Brushing: The surface is brushed with a wire brush to create a linear texture, This can improve slip resistance and corrosion resistance.

The choice of surface finish will depend on the requirements of the final product such as its aesthetic appeal, cost, function, durability, and corrosion resistance. Some finish options may have added cost, but it can improve the final product’s performance and lifespan.


Benefits and Limitations of Sheet Metal Fabrication

Precision: Sheet metal fabrication allows for the precise control of dimensions and tolerances, which is important for many applications, especially in the aerospace and automotive industries.

Customization: Sheet metal fabrication allows for the production of custom parts and products, which can be tailored to specific requirements and needs.

Cost-effective: Sheet metal fabrication can be a cost-effective method of producing parts and products, especially in large quantities.

Versatility: Sheet metal fabrication can be used to produce a wide range of products and parts, from simple sheet metal boxes to complex aerospace components.

Efficiency: With the help of modern technology such as CAD/CAM and CNC machines, sheet metal fabrication can be highly automated and efficient, improving turnaround time and reducing costs.

High-Volume Production: Sheet metal fabrication is suitable for high-volume production runs, which makes it a cost-effective solution for many products and parts.

Durability: Sheet metal is a strong, durable material that can withstand high stress and heavy loads.

Sustainability: Metal fabrication is environmentally friendly and produces minimal waste, and the majority of it is recyclable.

With the use of modern technology, sheet metal fabrication can be an efficient, automated process, and it offers a wide range of options to be tailored to specific needs and requirements. However, there are also some limitations of sheet metal fabrication including:

Capability limits per technique

High initial capital for tooling and equipment

Complex shapes and designs can be difficult and costly to produce using sheet metal fabrication techniques.

The thickness of the sheet metal is usually limited to less than 6mm, which means that it may not be suitable for some heavy-duty applications.

Some materials, such as plastic or composites, may not be able to be fabricated with sheet metal fabrication methods.

The design of the part needs to be well-defined and detailed to prevent errors during the fabrication process.

Overall, sheet metal fabrication is a versatile and cost-effective method of production, but it may not be suitable for all applications, and certain limitations may apply. Therefore, please do not hesitate to contact us as we have prepared everything you need to build your ideal finished products! Our experienced specialist will do it all for you from designing to producing the end products based on your requirements!

At Grille Tech Sdn Bhd, with the cutting-edge technology we use and supported by our experienced team which consists of multiple professionals, you can rest assured that we provide the best speaker grille, anodizing services and your desired customized finished products in Malaysia.


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