Making Sheet Metal Brackets: Ultimate Guide
Brackets are used as a secondary component to help in assembling different parts together. Manufacturing sheet metal brackets must be precise and it uses specific materials for a durable finish.
If you are looking for essential information on sheet metal brackets, the guide below can help.
What are Sheet Metal Brackets?
Sheet metal brackets are also called flat metal brackets which help in attaching one component to another. It helps to align parts together, which have an enclosure, by providing additional support. The type of bracket determines whether it is welded with the sheet metal component or mounted with the hardware.
How Do We Process Sheet Metal Brackets?
The sheet metal bracket manufacturing process has different stages, and these are discussed below:
Cutting
The stage of cutting consists of using a laser cutter to cut the metal sheet based on the given size requirements.
Forming
The metal piece that is cut is bent either at one or multiple angles and uses a press brake so that the required shape is attained.
Punching
The punching process helps in creating holes in the sheet metal bracket so that it can be mounted on the walls.
Welding
Brackets, which are meant to turn the materials to be stiff, are welded together.
Different Types of Sheet Metal Brackets
There are different types of sheet metal brackets, each with a different shape to suit multiple purposes. The different sheet metal bracket designs are discussed below.
L-Bracket
The L-bracket is the most common one, consisting of a single bend that creates the L-shape. It is bent at 90 degrees and can go up to 120 degrees.
U-Bracket
U-brackets are the ones that have two bends, which create a U-shape. They are longer than L brackets and need multiple holes to mount with the hardware. These brackets are suitable for mounting surfaces that are parallel to one another.
Z-Bracket
Z-brackets are the ones that have parallel flanges in opposite directions with two bends. They make a Z shape and are used to attach components at different levels.
Gusset Bracket
Gusset brackets are added to the metal parts to enhance their fortification. They have a triangle shape and are used in applications associated with infrastructure like bridges.
Offset-Bracket
An offset bracket is a type of bracket that has a multipurpose plate. It helps to keep the frames attached to the walls and is ideal for steel hangers that have a rectangular shape.
Hat Channel Bracket
The hat channel brackets are hat-shaped brackets that have been welded within the parts and are made using weak materials. It keeps the parts protected against collapsing inwards.
Materials for Crafting Sheet Metal Brackets
There are different materials that are opted to craft sheet metal brackets, and these are as follows:
Steel
Steel is a very strong and durable material that is used in many structural applications. It is easy to alloy with other metals, and the corrosion resistance and other properties can be improved.
The applications of steel brackets are seen in construction, automobile, and manufacturing; these are heavy-duty brackets used in high-strength applications.
Stainless Steel
Stainless steel is resistant to corrosion and staining. It offers excellent durability in harsh environments. It is used for manufacturing brackets, which are used in marine, medical, and food processing applications.
Aluminum
Aluminum is always known for its lightweight structure and excellent electrical conductivity. Aluminum brackets are popular in aerospace and electronics due to their high strength-to-weight ratio.
Brass
Brass is an alloy of zinc and copper and is known for its excellent aesthetic appearance, electrical conductivity, and corrosion resistance.
It is used in applications that require aesthetics and functionality. Applications like hardware, electronic components, and musical instruments tend to use brass brackets.
Surface Finishes for Sheet Metal Brackets
There are different surface finishes for sheet metal brackets, and some of these are as follows:
Powder Coating
Powder coating uses dry powder, which is applied electrostatically to the surface of the sheet metal bracket. After application, the bracket is left to cure under heat so that a tough layer is created to keep the bracket from chipping.
Bead Blasting
The bead blasting process involves creating a uniform matte finish on the sheet metal bracket. The fine particles of glass or metal are blasted on the sheet metal bracket at high pressure and speed, which ensures that the surface of the bracket turns smooth.
Plating
The process of plating involves creating a layer of metal like zinc, nickel, or chromium on the sheet metal brackets, which makes them resistant to corrosion.
Anodizing
The process of anodizing is usually opted for aluminum brackets. The process converts the surface of the bracket equipped with an anodic oxide finish, which makes it durable.
Applications of Sheet Metal Brackets
There are many applications of sheet metal brackets, and some of these are as follows:
Automotive: The automobile industry uses sheet metal brackets in the exhaust system and vehicles' engines. These brackets offer stability in the structure and can withstand high temperatures.
Electronics: Sheet metal brackets allow us to assemble the enclosures and circuit boards, and they also help with cable mounting. These brackets help secure the electrical components better.
Construction: In construction applications, railings, beams, and panels are secured through these brackets. They also help count the shelves and frames. The sheet metal bracket provides a strong hold of these components against loads.
Aerospace: Aerospace applications use sheet metal brackets in fuel lines, navigation tools, and aircraft panels. The aluminum brackets are lightweight and enhance fuel efficiency.
Key Factors to Consider When Designing Sheet Metal Brackets
When designing the sheet metal brackets, some of the important factors to consider are as follows:
- The materials selected for manufacturing the sheet metal brackets should be corrosion-resistant, capable of handling weight, and within the budget.
- Ensure that when assessing the amount of weight, the bracket requires supporting so that the design takes into consideration that force to avoid deformation.
- The conditions in which the sheet metal brackets will be used are also a factor to take into account. Hence, choose a material that can withstand the surroundings.
- The design of the bracket should consider the appropriate bend radius, tolerance, and hole spacing so that it can be used for multiple purposes.
- The method of installing and securing brackets is also a point to consider to ensure secure installation.
Conclusion
Sheet metal brackets are meant to be used in many applications, and hence, it is important to ensure that the design considerations are aligned.
DEK offers custom sheet metal brackets designed with high precision for your projects, so get in touch with us today.
