What Is Metal Fabrication: Types, Processes and Applications

Metal fabrication transforms raw or semi-finished metals into use-end products through cutting, shaping, and molding. The process starts with raw materials that we cut, bend, and join to make finished parts for decorative, industrial, and structural uses.

Large-scale projects such as oil drilling platforms, ships, and bridges, as well as smaller components like engines, and even jewelry, are all manufactured through metal fabrication.

This article introduces the definition, advantages and disadvantages, processes, main types and applications of metal fabrication, read on together!

Pros and Cons of Metal Fabrication

Metal fabrication has numerous advantages that make it a popular choice for a wide range of industries. Likewise, it also has shortcomings, so here's a detailed look at these advantages and disadvantages in comparison.

Pros of Metal Fabrication

High Strength: Metal products typically have high strength and durability, making them suitable for load-bearing or high-stress applications.

Alta precisão: Modern techniques like CNC machining allow micron-level accuracy, making them suitable for precision parts in aerospace and medical device manufacturing.

Good Electrical & Thermal Conductivity: Ideal for electronics, power transmission, and heat exchange applications.

High Malleability: Can be shaped into complex forms through forging, casting, stamping, etc.

Recyclability: Metals can be melted and reused, making them eco-friendly and resource-efficient.

Wide Applicability: Used in industries such as construction, automotive, aerospace, robotics, semiconductor, and more.

Cons of Metal Fabrication

Custo elevado: Raw materials, equipment, and processing techniques are expensive, especially high-performance alloys like steel,aluminum 7075,titanium,invar,stellite,and kovar.

Difficult to process: Some metals, such as titanium and tungsten, are extremely hard and require specialized tools and techniques, increasing production difficulty and reducing efficiency.

Heavy Weight: Many metals (steel) have high density, which increases shipping and assembly costs..

Prone to Corrosion: Some metals (iron) are prone to oxidation and rust, requiring additional surface treatment such as electroplating and painting.

High Energy Consumption: Processes like smelting and forging require high temperatures and pressure, consuming significant energy.

Safety Issues: Processing may involve high temperatures, metal shavings, or toxic fumes, requiring strict safety measures.

Our experience shows that metal fabrication does have advantages in high-volume, long-term production runs. The upfront cost of metal fabrication may exceed that of plastic fabrication, but its durability and versatility are often worth the investment.

How does Metal Fabrication work?

Metal fabrication works through a series of steps that transform raw metal into finished products.

1. Material Selection

Based on project requirements, select steel, alumínio, or copper sheets from the workshop.

2. Machine and Process Selection

The actual manufacturing involves cutting metal using a laser cutter or bandsaw, bending metal with a press brake, and joining components via welding. Our CNC machines provide cutting precision within 0.005mm, enabling complex shapes.

3. Post-Finishing Treatments

The manufacturing process also includes post-processing options as needed to protect and enhance the metal’s strength and appearance. Punching creates holes in the sheet metal, while stamping forms specific patterns on the metal plate.

4. Quality Inspection

The final product undergoes precision testing, with quality checks throughout the entire manufacturing process to ensure the parts meet industry standards.

Main Types of Metal Fabrication Techniques

Now that we've explored how metal fabrication works, let's examine the main types of techniques used in the industry.

Industrial Metal Fabrication

Industrial metal fabrication refers to the technical process of forming, cutting, connecting, surface treating, and other operations on metal materials such as steel, stainless steel, and aluminum through mechanical, thermal, or chemical methods to manufacture parts, structural parts, or final products.

It is a core link in the global manufacturing industry and is widely used in aerospace, automotive, construction, energy, and other fields. The products manufactured include engine blocks, aluminum alloy shells, steel beams, and wind turbine towers.

Structural Metal Fabrication

Structural metal fabrication is the backbone of many large-scale projects. Metal fabrication produces metal frames that support buildings, bridges, and other facilities for industries such as construction, aeroespacial, and automotive that require high-strength structures.

Engineers primarily select specific materials such as carbon steel, stainless steel, or aluminum based on load requirements and environmental factors - steel remains the most common choice in structural applications due to its strength-to-weight ratio and cost-effectiveness. These materials are then cut, welded, and assembled according to precise engineering specifications using techniques such as TIG and MIG welding, strictly adhering to industry standards.

Let's take a look at some of the types of metal parts that may be used in structural projects:

Structural steel components, such as H-beams, I-beams, C-beams, angle steels, and T-beams, are important components that support bridge construction.

Connectors and fasteners are usually used for rigid connections at steel structure nodes.

Metal bearings, such as sliding bearings and seismic bearings, are usually used for bridge or equipment seismic isolation.

Steel ladders and handrails are often made of stainless steel or galvanized steel, and have certain requirements for durability and strength.

Commercial Metal Fabrication

Commercial Metal Fabrication is the process of machining metal materials into standard or customized products in response to market demand.

Compared to structural components, commercial metal parts tend to be smaller, more precise, and more flexible in production. They are typically used in construction and decoration, electronics and appliances, medical and food equipment, and other locations.

Common commercial metal products are listed below:

• Metal curtain walls
• Railings
• Hardware
• Electric car frame
• Caixas de proteção
• Radiator
• Surgical Instrument Racks
• Equipamento de processamento de alimentos

In addition to the three metal fabrication technologies introduced above, there are also Custom Metal Fabrication (for prototyping services), Ornamental Metal Fabrication, Sheet Metal Fabrication and Electrical Metal Fabrication.

Main Processes in Metal Fabrication

Metal fabrication transforms raw materials into finished products through various techniques. We at DEK employ these key processes to meet industry standards and ensure on-time delivery for our clients.

Fundição

Casting is one of the basic processes of metal fabrication.

Basic Definition: Casting refers to complex alloy parts made by pouring molten metal into specially designed molds to be cooled and solidified into a specific geometric shape. The main types of casting include sand casting, investment casting and pressure mold casting.

Process:

1. Create mold cavities
2. Pour in molten material
3. Cool and solidify
4. Remove the cast product

Applications: lightweight engine parts, chassis rotating parts for the automotive industry; turbine blades, fuel system parts, landing gear parts for aerospace; MRI machine housings and CT scanner frames for the medical industry.

Cutting

Cutting is the basis of metal processing. Before finishing, metal materials are often cut to divide large pieces of metal into smaller usable parts.

Common cutting methods include grinding wheel cutting, flame cutting, saw cutting, plasma cutting, laser cutting and water jet cutting.

Punching

Punching is the process of separating the material in the hollow portion of a part with intact material between a punch and a tool to obtain a hole of the appropriate size, and is commonly used in the high-volume production of metal parts.

Punching uses specialized punching machines to create precise holes in sheet metal to meet a variety of needs in light and heavy metal manufacturing.

Drawing

Drawing applies tensile force to pull metal through a tapered die, creating thinner metal shapes with precise dimensions.

This technique transforms flat sheets into useful forms like cylindrical vessels and box-like containers.

Bending

Bending is a metal processing technology that is mainly used to bend metal materials into specific angles and shapes. Bending is the basic process of metal forming, and its core lies in the precise control of angles, radii and springback.

Comparative Table of Bending Characteristics for Seven Metals

Welding

Welding, typically referring to metal welding, is a fabrication process that joins two separate objects into one integrated piece by means of heating, applying pressure, or both simultaneously. This creates atomic-level bonding forces between the materials to achieve a unified structure.

Based on the state of metal materials during the welding process, welding methods are categorized into three major types: fusion welding, pressure welding, and brazing. Common welding techniques include Tungsten Inert Gas (TIG) welding, Metal Inert Gas (MIG) welding or Gas Metal Arc Welding (GMA) to meet different project needs.

TIG Welding:

Provides excellent control over heat input, making it ideal for joining thin metal sheets and root pass welding. It is particularly suitable for welding metals such as aluminum and magnesium, which tend to form refractory oxides.

MIG Welding:

Similar to Soldadura TIG, except that it uses a consumable metal wire instead of a tungsten electrode in the torch. The wire is fed automatically from a spool by a motor-driven roller according to welding requirements, with the heat source being a DC electric arc.

GMAW (Gas Metal Arc Welding):

Refers to the use of a consumable electrode with shielding gas to perform narrow-gap welding.

Machining

Machining is another method of metalworking that focuses on removing material from a workpiece and shaping it. Let's take a look at the main processes including milling,turning and drilling to create precision metal parts.

Fresagem

Milling is a high-precision machining method that uses a rotating, multi-edged tool to cut through a workpiece. The focus of milling is to increase the metal removal rate (MRR), which can be achieved by significantly increasing the cutting speed or feed per tooth to achieve higher productivity.

There are various types of milling operations, including face milling, plain milling, angular milling, form Milling, and more.

Virar

Turning is a part of machining. Lathe machining mainly uses turning tools to turn rotating workpieces and is mainly used to process symmetrical rotating body parts, such as shaft parts, internal and external cylindrical surfaces of disk parts, and tapered threads.

The most common turning operations include facing, grooving, cutting, threading, drilling, boring, knurling and tapping.

Perfuração

Drilling is a CNC machining process that uses rotating drill bits to create precise holes in workpieces. It's essential for parts requiring fastener holes or internal channels.

Common operations include spot drilling, deep-hole drilling, reaming and countersinking. CNC ensures high accuracy and consistency across production runs.

Shearing

Shearing is a metal fabrication process that cuts flat sheet metal into desired shapes or dimensions by applying shear force, primarily used for straight-line cutting.

This process is compatible with various metallic materials including aluminum, steel, stainless steel, brass, and bronze. It enables rapid cutting with clean edges, making it particularly suitable for high-volume production..

Forjamento

Forjamento is a processing method in which pressure is applied to a metal blank through hammering, pressing, or rolling, causing plastic deformation to produce forgings with specific mechanical properties, shapes, and dimensions.The main types of forging include open-die forging, hot forging, and cold forging.

Estampagem

Stamping transforms flat metal sheets into specific shapes through pressure and impact.

Stamping can achieve metal processing of complex geometric shapes, suitable for high-volume production, with material utilization rates exceeding 90%.

Four Types of Stamping Process

Which Metals are Usually Fabricated?

The various properties of metals play a crucial role in the field of machining, with each metal possessing unique characteristics that influence production operations and applications. Let us delve into some commonly used metals and the reasons they are suitable for metal fabrication.

Aço

Steel is one of the most widely used metals in our metal system, with strength, durability and plasticity. It is widely used in construction, automobile and industrial fields.

High strength: suitable for bearing high loads, widely used in structural parts and mechanical parts.

Machinability: Steel is easy to process into complex shapes through various processes such as forging, stamping, cutting, welding, etc.

Wear resistance: Through alloying or quenching, high wear resistance can be obtained, suitable for making tools and molds.

Aço inoxidável

Stainless steel is a highly corrosion-resistant alloy widely used in industries requiring hygiene, strength, and longevity. It is essential in construction, medical equipment, and food processing.

High corrosion resistance: Resists rust and stains due to chromium content, ideal for harsh environments.

Strength & durability: Maintains structural integrity under stress, used in bridges, buildings, and machinery.

Hygienic properties: Non-porous surface makes it perfect for medical tools and kitchen appliances.

Machinability: Can be welded, cut, and formed, though some grades require specialized tools.

Alumínio

Aluminum is a lightweight, versatile metal known for its excellent strength-to-weight ratio and corrosion resistance. It is widely used in aerospace, packaging, and transportation.

Leve: About one-third the weight of steel, ideal for aircraft and vehicles.

Corrosion resistance: Forms a protective oxide layer, suitable for outdoor and marine applications.

Conductivity: Excellent thermal and electrical conductor, used in power lines and heat exchangers.

Recyclability: 100% recyclable without quality loss, making it eco-friendly..

Cobre

Copper is a highly conductive and malleable metal, essential in electrical wiring, plumbing, and electronics.

Electrical conductivity: Best among non-precious metals, crucial for wiring and circuits.

Thermal conductivity: Used in heat exchangers, radiators, and cookware.

Antimicrobial properties: Kills bacteria, making it useful in hospitals and water systems.

Ductilidade: Easily drawn into wires or hammered into sheets without breaking.

Latão

Brass is a copper-zinc alloy valued for its gold-like appearance, machinability, and acoustic properties. Common in musical instruments, fittings, and decorative items.

Corrosion resistance: Resists tarnishing, suitable for marine and plumbing applications.

Machinability: Softer than steel, easy to cast, forge, and polish.

Acoustic quality: Used in bells, wind instruments, and ammunition casings.

Aesthetic appeal: Polished brass is decorative for fixtures, jewelry, and antiques.

Applications of Metal Fabrication

Metal fabrication powers many industries across the globe. Below are some of the areas where metal fabrication can be applied:

Aeroespacial

Metal fabrication is critical in aerospace for manufacturing aircraft, spacecraft, and propulsion systems. Key applications include:

Airframes: Aluminum and titanium alloys are fabricated into fuselage panels, wing spars, and ribs to balance strength and weight.

Engine Components: High-temperature superalloys are machined into turbine blades and combustion chambers.

Precision Systems: Hydraulic and fuel systems rely on CNC-machined fittings and welded tubing.

Additive Manufacturing: 3D-printed metal parts reduce weight in satellites and drones.

Automóvel

From traditional vehicles to EVs, metal fabrication enables mass production and innovation:

Body Structures: Steel stamping forms car doors, hoods, and crash-resistant frames.

Powertrains: CNC-machined engine blocks and forged crankshafts ensure durability.

EV Batteries: Laser-cut aluminum housings protect battery modules from impacts.

Custom Parts: Robotic welding assembles exhaust systems and suspension components.

Médico

Precision metal fabrication ensures safety and functionality in healthcare:

Surgical Instruments: Stainless steel is milled into scalpels, forceps, and implants.

Diagnostic Equipment: Copper alloys shield MRI machines from interference.

Prosthetics: Titanium rods are CNC-machined for lightweight, biocompatible limbs.

Sterilization Tools: Autoclaves and surgical trays rely on corrosion-resistant welding.

Energia

Metal fabrication powers renewable and traditional energy systems:

Oil & Gas: Pipelines are fabricated from high-strength steel to withstand pressure.

Wind Turbines: Tower sections are rolled and welded from steel plates.

Solar Farms: Aluminum frames support photovoltaic panels for corrosion resistance.

Nuclear: Radiation-resistant zirconium alloys are machined

Eletrónica

Miniaturized metal parts enable modern devices:

Circuitry: Copper is etched into conductive traces on PCBs.

Heat Sinks: Aluminum fins dissipate heat in CPUs and LEDs.

Connectors: Gold-plated brass contacts ensure reliable signal transmission.

Conclusão

Through the above introduction, we have learned about the advantages and disadvantages of metal processing, processing, types, processes, metals and applications.

To ensure high-quality components, you need to understand the different manufacturing processes and choose the right materials to achieve precise results. DEK will provide you with all your metal processing needs. Our team will turn your ideas into reality with first-class technology, service and on-time delivery.

Whether you need custom metal parts, prototype design, or small or large-scale production, DEK's advanced manufacturing capabilities ensure competitive prices, fast turnaround times and excellent precision.