Sheet Metal Fabrication: Step-by-Step to Efficiency
In Focus
Are you looking for sheet metal fabrication? Are you unsure where to begin, who to contact, or what your options are?
Finding the right option when it comes to sheet metal fabrication comes down to a few key steps:
- Drawing/print review
- Fabrication method evaluation
- Cost/benefit analysis
The process for each is highly dependent on the type of part being produced and the project requirements. Let’s take you through the process using a hypothetical part being produced from the metal sheet with the following requirements:
A quarter-inch thick high-strength low-alloy material
The need is for approximately 1,000 pieces to be produced annually
The challenge is to analyze the drawing and select the optimal manufacturing method, considering both precision and cost. We will primarily focus on the initial cutting processes, leaving the forming process on a press brake for a later stage.
Step One: Understanding the Drawing
Commencing with a meticulous review of the drawing, particularly focusing on tolerances and key features, is paramount. The analysis begins with the title block, unraveling critical information governing the fabrication process. Tolerances, specified at plus or minus ten-thousandths of an inch, set the stage for our decision-making journey.
Step Two: Evaluating Sheet Fabrication Methods:
Eliminating methods that don't meet the required precision is critical in the decision-making process. In this evaluation, we focus on key features that demand tight tolerances, specifically homing in on a 3.45-inch diameter hole and a slot in the upper right-hand corner of the component. These features, governed by tolerances of plus or minus ten-thousandths of an inch, set the bar for precision in our fabrication process.
The analysis reveals that plasma cutting fails to achieve the necessary precision, rendering it unsuitable for this project. This elimination process leaves us with two promising contenders: hard tooling (stamping) and laser cutting combined with forming on a press brake.
The analysis reveals that plasma cutting fails to achieve the necessary precision, rendering it unsuitable for this project.Here is a closer look at each:
Hard Tooling (Stamping):
Hard tooling, or stamping, is a conventional method known for its efficiency during full-scale production. However, its viability hinges on the volume of the production run.
Custom tooling tailored to match the part's design can be a powerful solution when producing a large quantity of components. Despite its effectiveness, there are challenges associated with hard tooling, notably the substantial upfront costs and lead time.
Custom tooling, which may involve intricate dies and molds, can incur expenses reaching tens of thousands of dollars. Furthermore, custom tooling can take months to produce usable parts for the project. While hard tooling may be the optimal choice for high-volume projects, its drawbacks become apparent when the volume doesn't justify the significant investment.
Laser Cutting Combined with Forming on a Press Brake:
In contrast, laser cutting coupled with forming on a press brake is a compelling alternative. Laser cutting, a soft tool method, offers a precise and efficient solution. The technology's ability to meet tight tolerances outlined on the drawing positions it as a favorable choice.
Laser cutting also provides design flexibility, allowing for future modifications or design changes without the need for costly tooling reinvestment. Additionally, the lead time associated with laser cutting is significantly reduced, enabling us to manufacture and ship initial parts in a matter of weeks.
This combination of precision, flexibility, and rapid turnaround makes laser cutting the optimal processing method for this specific sheet metal fabrication project.
Step Three: Annual Quantity Consideration:
The annual quantity required for this project becomes a pivotal factor in our decision-making process. With demand set at approximately 1,000 pieces per year for this project, we must carefully weigh the advantages and disadvantages of each manufacturing method.
Hard Tooling (Stamping) in Full Production:
Hard tooling shines in scenarios of large-scale production. The efficiency and cost-effectiveness of stamping become more pronounced when producing a high volume of components.
However, the substantial upfront costs of creating custom tooling pose a considerable hurdle. The investment in stamping tooling, which could reach tens of thousands of dollars, becomes less justified when the annual volume is insufficient to offset these costs.
Moreover, the extended lead time required for producing custom tooling could delay the delivery of usable parts to the customer for several months.
Laser Cutting Combined with Forming on a Press Brake:
On the other hand, laser cutting combined with forming on a press brake proves to be a more agile and cost-effective solution for the given annual quantity. The technology's precision meets the project's requirements without the need for custom tooling.
... laser cutting combined with forming on a press brake proves to be a more agile and cost-effective solution for the given annual quantity.The absence of substantial upfront costs and the rapid turnaround associated with laser cutting make it a more viable option in this scenario. The ability to manufacture and ship initial parts in a matter of weeks aligns with the customer's demand for prompt delivery.
While hard tooling might be economically advantageous in full-scale production, laser cutting is the more pragmatic choice for this project's specific parameters, offering a harmonious balance between precision, cost-effectiveness, and efficient project completion.
Cost vs. Benefit Analysis:
The equation compares the cost delta between laser cutting (a soft tool method) and forming on a press brake against the expense of stamping tooling. In this case, the answer is a clear no. Laser cutting is the optimal choice due to its cost-effectiveness and ability to meet precision requirements.
Laser cutting emerges as the solution, providing the most viable manufacturing method at the best price point. Its precision meets drawing requirements, and it offers design flexibility crucial for future modifications without reinvestment in tooling.
Laser cutting significantly reduces lead time, enabling prompt manufacturing and shipment.
Trust in Sheet Metal Fabrication Specialists
To reiterate, each project is different based on specifications and requirements. This hypothetical scenario is meant to give you a sense of the process a good metal fabrication partner should bring to the table.
This exemplifies Ryerson's commitment to delivering optimal solutions in sheet metal fabrication. Laser cutting is the chosen method in this example, showcasing our dedication to precision, cost-effectiveness, and efficient project completion.
Have a project you'd like us to review? Upload a print here.