Ultimate Guide to Custom Sheet Metal Fabrication Processes

Sheet metal fabrication is the method of manufacturing products by manipulating thin metal sheets through cutting, bending, and shaping. The products can range from simple structures like brackets and enclosures to more intricate components utilized in multiple industries. Furthermore, this process encompasses custom techniques that allow precise and tailored solutions to meet specific needs.

Eugenio’s Sheet Metal has been offering top-notch fabrication services since 1973. We specialize in sheet metal prototyping and handling mid-volume production runs. We also possess a vast collection of manual and automated metal forming, welding, and finishing technologies to facilitate fabrication.

Benefits of Utilizing Sheet Metal for Fabrication

Sheet metal fabrication is the preferred manufacturing method for many manufacturers due to its numerous advantages. From the sheet metal’s versatility and affordability to its strength-to-weight ratio and customizability, it provides the following benefits:

  • Versatility
    Sheet metal comes in different thicknesses, which can be selected based on the application’s specific requirements. For example, thin sheets can create small, intricate parts, while thicker ones can make larger components requiring greater strength.

    This material can also be manufactured from various materials — such as steel, aluminum, copper, and brass — with unique properties. This versatility allows for greater final product customization based on its intended application.
  • Cost-Effectiveness and Availability
    Compared to materials like plastics or composites, sheet metal is a cost-effective choice for manufacturers requiring large parts. Additionally, it is readily accessible, allowing for seamless integration into manufacturing processes. This blend of cost-effectiveness and availability makes it suitable for small and large-scale businesses.
  • Customizability
    Customization is an essential part of manufacturing since it enables the fabrication of components that meet individual design requirements. The high degree of customizability sheet metal offers simplifies manufacturing parts and components that adhere to precise standards. In addition, modern machinery and methods make it easy for manufacturers to manipulate the material into the necessary forms and dimensions.
  • Durability
    Sheet metal is widely recognized for its sturdiness and durability, making it a top preference for applications that demand high strength and extended lifespan. The components can also withstand rigorous conditions and intensive usage, making them highly suitable for the construction, automotive, and aerospace industries.
  • Sustainability
    Most sheet metals are made from recycled materials, which are both environmentally friendly and energy-efficient. They may also be recycled repeatedly without degrading performance quality, substantially reducing the quantity of waste produced throughout the manufacturing process.

Common Sheet Metal Fabrication Processes

Various methods are utilized in custom sheet metal fabrication to produce parts and components that satisfy precise design specifications. This means that manufacturers have access to an array of tools and processes that can be utilized to achieve the desired result.

Here are common techniques and specific processes under them:

Press Brake Forming

Press brake forming is a bending method that shapes sheet metal into a specific configuration using a press brake. The press brake uses a punch and dies to apply force onto the metal, resulting in the desired angle. Examples of shapes and angles include U-shapes, L-shapes, and V-shapes.

Plasma Cutting

Plasma cutting is a metal cutting technique that utilizes a high-temperature jet of ionized gas to melt and expel the cut material and reach 20,000 °C. An electric arc is generated between the cathode electrode and the anode workpiece, which is then constructed by a water- or air-cooled gas nozzle.

Ring Rolling

Ring rolling is a metal forming technique to create seamless rings or cylindrical components. It compresses the metal between two or more dies that come closer and mold it into a ring shape. This process helps produce various parts like flanges, gears, and bearing races.


Sheet metal punching is a widespread metalworking technique critical in modern manufacturing. This method uses a punch die tool to penetrate the sheet metal, producing a hole through the shearing process.


Shearing is a cutting process that divides large sheets into smaller sections or carves out particular shapes. It utilizes a sharp blade or punches to create a precise break along a predetermined line to separate the metal.


Metal stamping is a technique that transforms planar metal sheets into particular configurations. It is a multifaceted process encompassing various metal-forming methods, such as piercing, bending, punching, and blanking.

Tube Bending

Tube bending is a metal fabrication method to permanently shape pipes or tubes. Although typically used on circular tubes or pipes, it can also be applied to square, rectangular, or other tube configurations.


Welding applies heat, pressure, or both to fuse two or more parts and forms a joint as the parts cool. It differs from brazing and soldering, which do not melt the base metal since it requires high temperatures.
  • Arc Welding: This utilizes an electric arc between a consumable electrode and the workpiece to produce heat for melting and fusing the metal.
  • Metal Inert Gas (MIG) Welding: This feeds a spool of metal wire through a handheld gun and uses an electric arc to melt the wire and base metal together.
  • Tungsten Inert Gas (TIG) Welding: This uses a non-consumable tungsten electrode to create an angle that melts the metal while a separate filler rod is added to the joint.
  • Spot Welding: This applies pressure and an electric current, resulting in a resistance that melts the metal and causes it to fuse.

Common Materials Used in Sheet Metal Fabrication

Sheet metal is widely used in fabrication due to its adaptability, longevity, and affordability. Various types of metals are utilized in fabrication, each with distinct features and attributes. Below are some of the most prevalent materials employed in the manufacturing process:

  • Steel
    Steel is typically used in fabrication because of its strength, durability, and widespread availability. It is also obtainable in various grades and finishes, allowing it to be used in multiple applications.
  • Aluminum
    Aluminum is a flexible and lightweight sheet metal material with a favorable strength-to-weight ratio, making it applicable for various uses. Its high corrosion resistance also makes it ideal for use in outdoor and marine environments. Moreover, it is easy to shape and form, which allows for creating complex designs and smooth finishes.
  • Stainless Steel
    Stainless steel possesses exceptional strength, corrosion resistance, and aesthetic appeal. This makes them perfect for applications requiring high levels of hygiene and cleanliness, such as in the medical and food processing industries. Furthermore, it has exceptional durability, making it an economical choice for long-term use.
  • Brass
    Brass is an excellent sheet metal material with several advantages, such as high ductility, excellent acoustic properties, and high corrosion resistance. In addition, due to its attractive golden appearance, it is widely used to manufacture musical instruments, plumbing fixtures, and decorative items.

Key Considerations for Selecting the Right Custom Sheet Metal Fabrication Partner

Choosing the appropriate metal fabrication company is critical for any project, whether for new construction or upgrading current products. The following are vital factors to take into account when making a decision:


The company’s ability to meet strict specifications largely depends on its experience. However, relying solely on the company’s years of experience in the industry may not always guarantee the latest technologies. Therefore, ensuring that their existing team has worked on similar projects is important. It is advisable instead to request references from previous clients and speak with other customers about their experiences.


Maintaining quality standards is essential in custom metal sheet fabrication, particularly in ensuring the durability and longevity of manufactured metals. Aside from regulatory requirements, products, and equipment must pass internal quality checks that meet or exceed project specifications.


Working with a partner with access to cutting-edge metal technology is optimal for custom metal fabrication. Choose a company specializing in automation, which might reduce the likelihood of costly errors.

Customer Service

Excellent customer service is a cornerstone of a successful and long-lasting partnership with a metal fabrication company. Therefore, choosing a manufacturer that prioritizes proactive communication and provides regular progress reports throughout the project is important.

Eugenio’s Sheet Metal: Your Trusted Sheet Metal Fabrication Partner

With over 50 years of experience, Eugenio’s Sheet Metal specializes in prototyping sheet metal fabrication and mid-volume production runs, utilizing manual and automated technologies! We work with various materials, including steel, aluminum, copper, brass, and stainless steel.

Contact us today or request a quote to start on your project today.

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