Effective Strategies to Reduce Sheet Metal Fabrication Costs

Sheet Metal Fabrication Costs

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.

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Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Aluminum 6061602.68193117
Aluminum 6063732.721468.9
Aluminum 70501472.83490160
Aluminum 7075(Aerospace Grade)1502.81503159
Aluminum MIC-6652.7105N/A
Aluminum 5052602.68193117
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Fatigue Strength (MPa)
Copper 10165 - 908.89 - 8.9469 - 36576 - 90
Copper C11065 - 908.8969 - 36576 - 90
Copper C17280 - 858.25515 - 585275
Copper C26060 - 828.53103 - 44190
Copper C36063-1308.49124-310138
Brass CZ12190 - 1608.47360 - 500220 - 360
Brass CZ13170 - 1408.5340 - 480200 - 350
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Stainless Steel 17-73887.812752046
Stainless Steel 3012178.0320521240
Stainless Steel 3031608.0324020050
Stainless Steel 3161878.0320519340
Stainless Steel 3322008.0329419644
Stainless Steel 4163607.89622009.5
Stainless Steel 4205067.8104020011.5
Stainless Steel 440C495 - 6537.8450 - 1900204 - 2152.0 - 14
Hardness(Shore D)Density (g/cm^3)Modulus of Elasticity (GPa)Tensile Strength(MPa)Elongation at Break(%)
HDPE50 - 760.92 - 0.990.565 - 1.511 - 433 - 80
UHMW-PE54 - 1200.8 - 1.80.3 - 1.111.6 - 403.5 - 800
PVC801.16 - 1.651.82 - 7.033.45 - 73.12 - 330
ABS/Nylon Blend641.04 - 1.210.9 - 5.327 - 1003.1 - 230
Acrylic600.7 - 1.30.95 - 3.7925 - 851 - 85
Nylon 6676 - 881.02 - 2.70.6 - 2510 - 981 - 300
PTFE11 - 700.7 - 3.350.392 - 0.750.86 - 41.470 - 650
PEEK62 - 941.26 - 1.722.14 - 2411 - 1251.7 - 100
POM-H811.423.27530
POM-C791.412.86740
Hardness (Brinell)Density (g/cm^3)Tensile Strength(MPa)Modulus of Elasticity (GPa)Elongation at Break(%)
Titanium(Grade 1)1204.5170 - 31010324
Titanium(Grade 2)2004.51276 - 44810320
Titanium(Grade 4)2654.51480 - 65510515
Ti-6Al-4V(Grade 5)3794.43110011410
Bronze11.6 - 4205.6 - 1469 - 80072.4 - 1380 - 70
Zinc Alloy (Zamak 5)916.720870 - 1007
Steel Alloy AISI 43403887.8597220012.1
Nickel Alloy175 - 2408.44414 - 75820716