Sheet metal fabrication is a multi-step process that transforms raw sheet metal into finished components, involving cutting, bending, forming, and assembly. The workflow varies based on part complexity but generally follows a structured sequence to ensure precision and efficiency.

The process begins with design and prototyping. Engineers use CAD (Computer-Aided Design) software to create detailed 3D models, which are then converted into 2D drawings for manufacturing. Prototyping, often using laser cutting or 3D printing, allows for testing and refinement before mass production.

Next is material selection and preparation. Sheet metal materials such as steel, aluminum, copper, or stainless steel are chosen based on mechanical properties (strength, ductility) and application requirements (corrosion resistance, conductivity). The raw sheets are cut to size using techniques like laser cutting, which offers high precision for complex shapes, or plasma cutting for thicker materials. Shearing is used for straight-line cuts in high-volume production, while waterjet cutting is preferred for heat-sensitive materials to avoid thermal distortion.

After cutting, the sheet metal undergoes forming processes. Bending is performed using press brakes, where the metal is folded along a straight axis to achieve angles (90-degree bends are common). Roll forming is used for creating continuous curved shapes, such as pipes or channels, by passing the sheet through a series of rollers. Punching and stamping use dies to create holes, slots, or embossed features, with progressive stamping enabling multiple operations in a single pass for high efficiency.

Welding and assembly follow, where individual components are joined using methods like MIG (Metal Inert Gas) welding, TIG (Tungsten Inert Gas) welding, or spot welding, depending on material thickness and strength requirements. Riveting or bolting is used for non-permanent joints. Finally, surface treatment (as discussed earlier) is applied to enhance durability and appearance, followed by quality inspection using tools like calipers, micrometers, or coordinate measuring machines (CMM) to ensure dimensions meet specifications.

This structured process flow, often automated with CNC (Computer Numerical Control) machines for precision, ensures that sheet metal components are produced efficiently, with consistent quality, meeting the diverse needs of industries such as automotive, aerospace, construction, and electronics.