Fabrication in simple terms defined as the process of making something from raw materials other than readymade products Well as in structural construction, fabrication is the process of cutting, bending, and moulding steel structures to create beams, columns in order to use it for construction to be good manners. Only the fabrication materials are giving priority to have a perfect and strong construction. Without the fabricated material, no one can use normal materials on construction.

Fabrication is a term used for several different methods of manipulating metals into different shapes. Metal fabrication is a process of turning the raw materials such as metals or alloys like structural steel into predetermined shapes for assembling to erect a custom prefabricated building to meet the demands of any commercial and industrial projects. Metal fabrication helps to bring any kind of customisation in a prefabricated building. So let’s understand fabrication better by looking at different fabrication processes or systems.

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Without the expertise of metal fabricators, we would be without many products that keep our lives running smoothly. Some everyday objects made from durable metals include tables and chairs, hand tools, automobile parts, nuts and bolts, pipes, structural elements for buildings, and other equipment.

Metal fabrication involves the cutting and shaping of metal, which will soon be assembled and formed into a product. This includes plate metal, formed and expanded metal, hardware, fittings, sectional metal, welding wire, and so many more. Read on to learn more about this fascinating process.

Metal Fabrication is a crucial process in the manufacturing and construction industry. This process converts raw materials into processed metal structures which are used to build machines, buildings, and bridges. Structural Steel is widely used in fabrication because it is – durable, flexible, tensile and affordable. Various types of steel sections are created using various fabrication processes. Some types of steel fabrication processes are listed below:

How does metal fabrication work?

Our homes and our workplaces could not operate without the dutiful fab shop. Fab shops are specialised metal fabricators. Contractors and manufacturers often contact fab shops to pitch special projects. After bidding for jobs based on detailed drawings, a contract is awarded to the metal fabricator. Blueprints are made, dimensions and specifications are clarified, and calculations are finalised. 

Of course, the kind of metal used is one of the most important decisions to settle. Many shops will be able to work with aluminium, copper, iron, silver, steel, stainless steel, magnesium, and more. Some shops specialise in a certain type of metal or fabrication process.

Types of processes

The following are different types of metal fabrication processes that occur after the initial stages of project planning:

Cutting

This is the first stage of any fabrication process. Steel is first cut using a saw, water jets, plasma torches and lasers. There are other techniques used for cutting, such as numerical control, chiselling, and shearing.

There are many ways to cut nowadays. The old standby is the saw. Others now include plasma torches, water jets, and lasers. There is a wide range of complexity and price, with some machines costing in the millions.

A sheet of metal is split into smaller sections by sawing, laser cutting, waterjet cutting, or plasma cutting. These tasks can be performed by CNC (computer numerical control) or power tools. Cutting is frequently the first step in a fabrication project. It does not always have to be a sheet of metal; sometimes, pre-shaped metals like bars can be cut. 

Die-cutting is a process that uses a die to cut material. Rotary die cutting employs a cylindrical die attached to a rotary press, flatbed die cutting uses a press to cut shapes out of thicker metals, and digital die-cutting involves computer-controlled lasers and blades.

Casting

Casting is the process by which molten metal is poured into a die to cool and harden over time to create a product. This is helpful when you need multiple identical parts–such as plumbing nozzles, brass nuts and bolts, or aluminium mounting plates. It is also a money saver because it fast-tracks a series of processes that might be used to make the same part (i.e. cutting, folding, stamping). 

A permanent mould casting is made from a steel or cast iron. The molten metal is poured, cooled, and removed. A sand casting will break away to reveal the part made. During die casting, metal is poured into a die and forced to maintain shape through applied pressure.

Welding

Welding involves attaching two pieces of metal to form a separate steel section or build a large structure. There are different types of welding processes which are used based on the metal and overall design of the structure.

We at Northern Weldarc, offer a wide range of services. We are a team of highly experienced, professional steel fabricators. Our facility includes a 5.5 acre secured yard with fencing and a 30,000 square foot storage facility. We are well equipped to handle all your structural steel production requirements.

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How are products such as car ramps and architectural brackets made? Thank welding, which involves bringing two metal parts together. This is accomplished through a combination of heat and pressure. There are four primary welding processes:

Stick or Shielded Metal Arc Welding (SMAW) joins metal together through the use of a high-temperature electric current that forms an electric arc between an electrode stick and the metals. The most common process is Metal Inert Gas (MIG) or Gas Metal Arc Welding (GMAW), which applies a shielded gas along a wire electrode with a constant and direct power source. To connect heavier metals like stainless steel, a tungsten electrode rod is employed through Tungsten Inert Gas (TIG) or Gas Tungsten Arc Welding (GTAW). Flux-Cored Arc Welding (FCAW)uses a tubular wire with flux inside and does not always need shielding gas.

Stamping and punching

Stamping uses a press to create indentations and raises metal in order to create specific shapes. This is how coins are manufactured.

In this process, the die is shaped in a way that there is a raised portion of the material. It is a lot similar to punching.

Stamping helps to convert the flat metal sheeting into various shapes. Though the process is similar to the process of punching, stamping doesn’t cut the material. Stamping uses the die that causes the material to be raised instead of penetrating the metal. For instance, metal stamping is used on coins where you get to see the words, currency amounts, and face of presidents stamped on the coin.

Punching uses a press to create holes in metal by placing the metal between a punch and a die. Holes are necessary for such things as fastening latches. Blanking is when a specialised punch works on a sheet to make multiple parts at once–the metal punched out is the final product.

Punching is the act of a punch and a die forming a ‘scissor’ effect on a piece of metal to make a hole in it. The punch and die must be the same shape and size of the desired hole. In some cases, the main piece of material is kept, as in when holes are added for fasteners. In other cases, the piece that is removed is the desired product-this is called ‘blanking’.

This is a process wherein a piece of metal is punched using a punch press to create a hole in it. The punch often passes through the work into a die. The punch and die have to be of the same shape as that of the desired size of the hole.

Shrinking

It’s not uncommon for fabrication companies to shrink the metal. Generally speaking, there are three main ways in which these companies shrink the metal, the first of which is tucking. Arguably the oldest method, tucking involves forcing the metal between a crack with a hammer, or by folding the metal over its edges with a tucking fork. Tucking has been used by automakers to produce some of the earliest-model sports cars.

A second method for shrinking metal involves the use of a lever-operated tool known as a shrinker. This tool has jaws that grab the metal from both sides, squeezing it together. It’s more accurate than tucking, but it’s also more time-consuming.

The third method for shrinking metal is heat shrinking. It involves heating a stretched sheet of metal with a torch and then waiting for it to cool off. As the metal cools, it will naturally contract; thus, allowing for a smaller size.

Bending

To bend metal, fabrication companies often use manual or powered hammers with press brakes and other related tools. The press brakes are used to coin or air-bend metal sheets into the desired shape and form. It offers a cleaner and more accurate bend. The metal is placed and secured on a flat surface, after which it is lifted to bend the metal at the appropriate angle. Metal brakes can achieve bends of up to 90 degrees, making them invaluable in fabrication.

Assembling

Assembling metal is achieved in several ways, with the most common being welding. Other options for assembling metal include binding with adhesives, using threaded fasteners, riveting, and bending in the form of a crimped seam.

Folding

Folding or bending is done by a process called press brake. Steel needs to be bent to create certain steel sections. This technique is used to coin or air bend metal sheet into form. The press brake technique has a set of dies which pinches the metal to form a crease. Nowadays there is offline programming software which makes press brake even more efficient.

This is a complicated process meant to bend metal at different angles and commonly involves a brake press to shape a sheet. Products such as shelf brackets or computer equipment are produced via this method.

Some parts need to be bent. The most common method is a press brake (or brake press). It has a set of dies that pinches the metal to form a crease. This operation can only be performed in very specific cases due to the movement of the part and the possible shape of the dies. Designing for Lean manufacturing, though, can help prevent complex shapes that slow down production. Sometimes using two different types of fabrication processes or two different pieces fastened together work better than one complicated piece.

Shearing

Straight upper and lower cutting blades, or a punch and die, are used to make a long cut and split sheet metal into two portions.

It is also known as die-cutting. This process is used to cut straight lines on the flat metal stock. During the shearing process, an upper blade and a lower blade are forced past each other with the space between them determined by a required offset.

Shearing is the process of making a long cut on a piece of metal. It is, in effect, just like the action of one of those paper cutters with the long chop-handle. This is done on sheet metal.

Extrusion

Extrusion is the process used to create objects of a fixed cross-sectional area, making the perfect shape of the material. The main usage of manufacturing processes of extrusion is its ability to create very complex cross-sections and work materials that are brittle. 

Check out Welding Terminology and Abbreviations

Machining

Machining a piece of material is a phenomenal technique to add value to the piece through the removal of some of its volumes. The developments in machining practices and technologies have made it possible for the manufacturers to achieve designs that were difficult to achieve in the past. The resultant component alterations and tolerances that were only achievable with the most advanced facilities can now be obtained using common equipment.

The development of advanced machining technologies offers companies an opportunity to develop new forms of added value and bring to the market more specialised products.

It is the process of removing unwanted materials from the metal to acquire a particular shape as required by the designer. This process involves various sub-processes. “It can be done on a lathe, where the material rotates against a cutting tool or in some other cutting machine, where a rotating tool is moved in a variety of ways against a stationary piece.”

In order to remove material from a piece of metal and shape it to your specifications, machining is used. Drilling will form holes, turning uses a lathe to rotate a piece and create a cylindrical shape, and milling uses a multi-point tool that will move against the metal to cut off unwanted material. These are done manually or through CNC machinery. 

This is a type of fabrication process that involves removing the excess material until the final desired shape is achieved. There are many machining types, such as:

Drilling – It involves the process of making cylindrical holes in a workpiece using a drill bit.

Turning – It involves the removal of excess material from a workpiece that is spun by the lathe.

Milling – It involves the use of a rotating cutting surface composed of several blades that create non-circular holes or unique designs in a workpiece.

There are many other types of fabrication processes that are less common than the ones in the list above. There are also constantly new types of fabrication methods being developed.

One such new type is called additive technology. In effect, a machine layers materials to form a part-something like a three-dimensional printer that prints in plastic or other materials.

Fabrication processes are particularly well matched to Lean. The motion of operators, their interaction with machines, and the need to manage inventory are all right in Lean’s power alley.

Fabrication processes are particularly well suited to implementing jidoka (autonomation) and hanedashi devices (auto ejectors). Both of those devices are prerequisites of the chaku-chaku line (load-load).

But there is one area where Lean can struggle. Some extremely large machines are well matched to the products they are making. But far too many big machines with too long of a changeover time drive up inventory and promote overproduction. It is best to ‘right-size’ machines and put them into work cells if possible. That helps create flow.

Fabrication processes are generally target-rich environments for continuous improvement. There are great chances for visual management and 5S to make processes run more smoothly. There are immense chances to reduce setup time to help smaller lot sizes. Kanban helps with knowing what to make—especially on the extremely large machines. Right-sizing machines can help make the flow better—smaller machines fit in smaller spaces that can be set up as dedicated lines for higher volume products.

The fabrication processes, as mentioned above, are the most common processes used during prefabricated building construction. The choice of the fabrication process depends on the needs of a particular application and will often vary especially when you need customised prefabricated solutions.

What items are manufactured using metal fabrication processes?

Blinds. The blinds that block excessive sunlight and help to keep interiors private are made of leaf metals, which undergo shearing and folding to take on the shape and consistency required to seal off windows from light and outside exposure.

Cans. Canned goods are sold in metal containers that consist of tinplate or aluminium leaf metals, which are formed into a circle. They are then welded shut at the seam and along the circumference of the adjoining bottom. Once the food product has been inserted, the lid is welded into place.

Handles. Doorknobs and handles are made of metals such as nickel silver and brass, which are cast and sometimes folded and sheared into the desired shape. Whether it’s an opener that consists of a straight or curved handle, or a flat or ball-shaped knob, the fabrication processes involved are complex yet similar.

Heaters. The enclosures of heating units consist of sheet metal, as do some of the internal components that make these machines function.

Locks. Of all the non-electronic features in a house or building of any kind, door locks contain the most complex mechanisms. The inner workings of the metal lock are designed for an exclusive key shape, which the lock must be die-cast to accommodate.

Keys. Once the die has been cast for a door lock, the key itself must follow. A lot of keys are made out of punched and stamped brass, but the stronger, more durable metal for keys is nickel silver.

Latches. For homes, buildings, and fences, latches are produced in a variety of designs, yet all are realised through metal fabrication. Shearing and die casts are common during the process, but some designs may also involve stamping, machining, and folding.

Pots. There are few everyday household items that embody the casting process as boldly as the cooking pot, the shape of which originates from a casting form that is filled with liquid metal during production.

Silverware. Eating utensils such as spoons, forks, and knives generally consist of sterling or nickel silver, which are cast or stamped into shape at metal fabricating facilities. A similar process is applied to cooking utensils and kitchen tools such as whips, graters, and openers.

Fans. Even though many of today’s indoor fans consist of plastic and fibreglass parts, many models still feature enclosures that are made of cut and folded metal. Check out The Ultimate Guide To 6G Pipe Welding

Chairs. The legs of a desk chair, as well as the underlying support structure, are generally made of casted metal. The processes of metal fabrication are more clearly pronounced on fold-up chairs, which feature bars and panels made of cut and folded metals.

Hinges. The hinges that connect doors to walls and cabinets consist of sheet metal, which is cut to shape and punched with holes that are fitted to fasteners. The process of folding is employed at the barrel, and this gives hinges their fixed axis of rotation.

Lamps. Light fixtures are made in full or in part of the cut, folded and cast metals, whether the fixture consists of a metal socket connected to a ceramic base, or a full-metal body, which is typical of gooseneck desk lamps.

Faucets. Sinks vary in their material makeup, but faucets are all made of metal. Faucets are generally made through the fabrication process of casting, as are the handles and connecting pieces.

Appliances. When it comes to appliances, metal fabrication is responsible not only for the shells of stoves, dishwashers, and refrigerators but also for toaster enclosures, blender bases and the pressing surface of a clothing iron.

Tools. Indoor and outdoor hand tools are typically produced through the metal fabrication processes of cutting, stamping and casting. Examples range from scissors and X-ACTO® knives to hammers, saws and bush trimmers.

Cables. The cables and cords that bring appliances electricity — and connect computers to the Internet — are mostly plastic on the outside. Yet the workings of each cable/cord are due to the wires within the plastic, as well as the connectors and prongs, which are produced within a die.

Sinks. While bathroom sinks are typically made of vitreous china, kitchen sinks consist of metals such as cast iron and steel, which undergo the casting and sometimes the folding processes before being embedded into countertops.

Fasteners. Regardless of whether a house or apartment building consists of a metal or wooden structural frames, the structural pieces are held together with fasteners like screws, nuts, bolts and sometimes rivets, all of which are products of the casting and stamping processes of metal fabrication.

Fabrication processes tend to have another great opportunity in continuous improvement—people. ‘Fab’ processes tend to be hot and grimy. Small metal shavings are everywhere, as are coolants and lubricants. Parts are often heavy. Smoke and debris are in the air. Safety concerns abound. To top it off, machines are unforgiving. They are designed to work with metal—hands and other body parts don’t even slow them down. They are extremely loud. Unless you have experienced it, is it hard to imagine the volume of the rapid punching of a piece of quarter-inch sheet metal. In short, fabrication processes often contain the lion’s share of the dirty, dumb, and dangerous work in a company.

Continuous improvement in general, and Lean specifically, provide you with a great avenue to focus on making your fabrication processes less disrespectful to your team.

Everyday Items Made from Metal Fabrication Processes