Sheet metal fabrication is a versatile and cost-effective manufacturing method, but costs can quickly escalate with unnecessary complexity. Manufacturers can reduce sheet metal fabrication costs by optimizing design and material choices. Here’s how to achieve cost-efficient sheet metal fabrication.
Optimize Material and Welding Choices
Material selection plays a significant role in controlling fabrication costs. Opt for common materials like Aluminum (6061-T6 or 5052-H32), Steel (CRS1008), or Stainless Steel (304-2B). These are not only cost-effective but also widely available.
For welded components, avoid pre-plated metals due to the challenges of safe welding. Instead, use uncoated cold rolled steel with post-fabrication coating or consider alternative joining methods like rivets when using pre-plated materials.
Simplify Bending and Design Features
Reducing complexity in bending and design elements is crucial. To utilize standard tooling, maintain internal bend radii within 0.030 inches or the material’s thickness. Avoid deep pockets, blind holes, and intricate chamfers that require specialized machining.
Streamlining your design allows for faster production with fewer costly adjustments, ensuring both functionality and efficiency.
Leverage Standard Components and Fasteners
Incorporating off-the-shelf components wherever possible can significantly cut costs. Adapt designs to accommodate readily available parts, avoiding the need for custom fabrication. Similarly, use standard fasteners from catalogs like PEM to reduce lead times and expenses associated with specialty hardware.
Streamline Documentation and BOMs
Clear and concise documentation helps prevent miscommunication during production. Include only relevant manufacturing details and mark critical specifications. Provide a detailed Bill of Materials (BOM) with specific part numbers, material types, and finishing requirements to facilitate smoother operations.
Optimize Finishing Processes
Delaying non-essential finishing operations such as silkscreening or engraving until later stages can reduce upfront costs. For part marking, consider economical methods like screen printing paired with clear powder coating instead of more labor-intensive engraving. Always balance finishing choices between cost and durability requirements.
By following these strategies, manufacturers can reduce sheet metal fabrication costs without compromising quality or functionality. Whether optimizing material choices or simplifying designs, the key is to strike the right balance between efficiency and practicality.