Your design is unique. Your prototyping solution should be too.
Our team of experts will develop custom metal fabrication solutions to meet your needs.
We have passed all ITAR certification audits and have proven to exceed ITAR criteria for all our operating and inspection systems.
We drive to hit our customer commitments every time.
We offer a variety of cost-effective, semi-automated tooling solutions that cost 15-30% of fully automated production tooling.
Our in-house welding experts can complete your part by fusing two or more parts together through heat, pressure or both.
Incodema is the industry leader in precision sheet metal engineering solutions for all the major market sectors of our economy, including electronics, defense, aerospace, life sciences and industrial. Based in Ithaca, NY Incodema by Fathom is a turnkey single source provider of all necessary services required to manufacture your parts from inception through completion.
Our comprehensive portfolio of manufacturing services allows us to support several material types giving us the flexibility and agility to serve our customers from prototype through production. As part of Fathom Digital Manufacturing, Incodema has access to a robust nationwide network of comprehensive additive and advanced manufacturing capabilities.
By leveraging technology through the latest advancements in innovative manufacturing equipment, Incodema looks forward to the opportunity to demonstrate our synergistic approach to finding the right manufacturing process for your project.
A sheet metal prototype can help eliminate the guesswork in manufacturing while reducing overall costs. Prototypes work as a physical example of a concept, making it easy to explain product features and benefits. Functional prototypes also allow for form, fit and function testing. A prototype allows a product or part to be evaluated to guarantee that it is to exacting specifications. By testing your design before mass manufacturing, material waste, labor, and costs can be reduced. Prototyping allows designers and engineers to learn more about the new product and enables the creation of marketing assets like photography and instructional manuals.
The first step is to ensure your design is suitable for the manufacturing process. Any number of sheet metal fabrication processes may be used to create your prototype from cutting processes to forming processes to finishing processes. The team of engineering experts at Incodema by Fathom will work with you to determine the best solution.
Need a part fast? Incodema specializes in rapid production. Standard lead times are below, but 24hr expedite options are available.
|1-50 flat part pieces||2 days|
|50-1,000 flat part pieces||5-7 days|
|1-500 formed parts||6-8 days|
|1-5 drawn part pieces||10-15 days|
|4 slide tooled parts||4-6 weeks|
Incodema by Fathom leverages powerful technologies to streamline the cutting process and handle even the toughest, high-value cutting challenges.
|Material Thickness||Tolerance||Kerf||Part Volume||Set Up Cost||Lead Time **||Notes|
|OMAX WATERJET||Up to 6″||0.005″- 0.015″||.020″/.040″||1 to 5,000||Low||6-8 days||Metal, glass, plastic, stone, rubber, Kevlar, carbon fiber, ceramics, etc. Taper up to 59°|
|MICROCUT™||.0005″ – 0.5″||0.0005″ -0.005″||0.009″, 0.011″, 0.0196″||1 to 5,000||Low||6-8 days||Metal, glass, plastic, stone, rubber, Kevlar, laminates, carbon fiber, ceramics, etc.|
|FIBER LASER||AL: 0.250″ SS: 0.375″ CRS: 0.500″ COP: 0.250″ Brass: 0.125″||0.002″ – 0.005″||.008″||1 to High-Volume||Low||6-8 days||Metals – Fast|
|WIRE EDM||0.001″ – 6″||0.0005″||0.005″||1-200 Is Best||Low||6-8 days||Conductive Metals, Carbon|
|* CHEM ETCH||0.005″ – 0.060″||Is +/- 10% of material thickness, .002″ min.||Equal to metal thickness||1- Infinity||$350 Min.||6-8 days||Metal Only. No Burrs. Beveled Edges. Half Etch and Holes.|
*Inner radius should be 100% of material thickness. Outer Radius should be 75% of material thickness.
**Dependent on geometry, volume and material: 24hr Expedite options available.
Need precision forming? At Incodema, we have developed a technique in which we turn an ordinary press brake into a manual progressive die. By combining this dynamic technique with our custom tooling made with in-house toolmakers, we can easily achieve even the most intricate and complex design specifications. In fact, this process is so precise that we refer to it as “sheet metal origami” on the shop floor.
While small, complex parts are our specialty, we also offer large format services in-house. We maintain a 300-Ton Press with a 36” x 72” bed in our Newark, New York facility to form parts that are too large for a traditional press brake. This equipment is ideal for small volume projects that require deep-drawn custom parts or large die sets with embosses and gussets.
Looking for more volume? No problem. Our mid to high volume solutions take advantage of lower tooling and setup costs than progressive die manufacturing and can include custom features such as gussets and embosses. All our tooling is designed and built entirely in-house, making Incodema your turnkey manufacturing supplier.
A few of our unique processes below:
Semi Automated Manufacturing
Looking for mid-to-high volume quantities? We offer a variety of cost-effective, semi-automated tooling solutions that cost 15-30% of fully automated production tooling.
Four slide and multi-slide manufacturing is ideal for small and intricate springs, brackets, electrical terminals, clips and battery contacts in high volume quantities. All tooling is designed and built in-house by the Incodema by Fathom team.
Our skilled and creative toolmakers design and create complex tooling solutions necessary to manufacture even the most challenging stamped parts. Many of Incodema’s hands-on operators possess engineering skills, and they are empowered to develop manufacturing solutions on the fly to keep the manufacturing process moving quickly and smoothly.
Post-processing and finishing is the essential final step of the manufacturing process. Most parts will require some sort of smoothing or painting when they come off a machine. Post-processing improves the quality of parts and ensures that they meet all their design specifications.
Our welding experts can complete your part by fusing two or more parts together through heat, pressure or both.
Incodema’s Welding Processes:
We maintain strategic partnerships with key suppliers of heat treating, plating and powder coating who understand our need for quality and speed. As part of the Fathom Manufacturing Platform, Incodema has access to a robust nationwide network of comprehensive additive and advanced manufacturing capabilities. All of Incodema’s processes are NADCAP certified and RoHS compliant. Fathom Manufacturing’s extensive certifications include ISO 9001:2015, ISO 9001:2015 Design, ISO 13485:2016, AS9100:2016, NIST 800-171 and ITAR.
While we make every effort to meet all customer design specifications during the fabrication process, occasionally post CNC machining is required to complete the part. Our in-house CNC machining centers allow us to post-mill features into your sheet metal components to successfully manufacture your parts while maintaining our fast turnaround times.
Whether your formed parts need intricate EDM tooling, waterjet cut tools, or more robust CNC machined tooling, our team of engineers and master tool makers can develop creative tooling solutions for your formed parts. Complex bending and precision are our specialty and we look forward to solving your most challenging design features.
Attention to detail is critical to our manufacturing process, and we can uniformly remove laser dross, mechanical burrs or sharps and other surface imperfections with our in-house deburring and finishing operations. Our processes range from hand sanding to automated deburring, tumbling and finishing equipment.
Incodema Inc. is registered under the U.S. Department of State’s International Traffic in Arms Regulation (ITAR). The U.S. Department of State’s Directorate of Defense Trade Controls (DDTC), under authority established by the Arms Export Control Act (AECA), administers ITAR. ITAR regulates the manufacture, export and transfer of defense articles, information and services.
ITAR registration recognizes Incodema as a manufacturer fully capable of supporting all military and homeland security projects in the U.S. In accordance with ITAR requirements, Incodema is entirely owned and operated by U.S. citizens. Incodema recognizes the critical importance of securing proprietary, classified and confidential information from foreign interests.
Fathom Manufacturing’s extensive certifications include ISO 9001:2015, ISO 9001:2015 Design, ISO 13485:2016, AS9100:2016, NIST 800-171 and ITAR.
Our team is here to support you in every step of the product development process. There is rarely one metal forming process that can achieve all the requirements of a design, so we also offer Design for Manufacturing (DFM) support. Our team of experts may identify alternative design features or processes that allows us to meet your specific design requirements faster and with a minimal loss of material. Feel free to reach out to our manufacturing engineers at any stage of your design process for guidance. Here are some common design requirements to keep in mind:
Want more sheet metal design tips?
Using sheet metal manufacturing technology to produce your prototype has many advantages, including:
A wide variety of industries use sheet metal manufacturing to produce their prototypes and final products. Sheet metal manufacturing can be used for:
No matter the industry, we have your sheet metal prototyping solution. Over our 20 year history, we have partnered with clients across several key industries including medical, defense, aerospace, electronics, automotive and industrial, and we are confident that our team can handle any of the technological and manufacturing challenges specific to your industry’s demands.
Browse examples of recently completed projects by process (such as laser cutting or press brake forming) in the gallery below. If you have any questions about which manufacturing process is best for your design, please do not hesitate to contact us.
Our lasers are known in the industry as the gold standard of laser cutter technology due to their incredible speed and accuracy.
A waterjet cutter is a machine tool process that can cut metal and composite materials with CNC accuracy and without heat affected zones. It works by pressurizing a combination of water and an abrasive material, such as garnet, and forcing it through a nozzle onto materials to form their desired shape. Abrasive waterjets are ideal for heavy gauge and tough applications and can cut materials with a thickness of up to 6 inches in both low and high quantities.
Our technicians use this machine to deliver a great, high-quality finish in a quick turnaround time. We can even achieve a mirror-like finish with this machine.
Our fully automated deburring system processes up to 3 metal sheets per minute without the use of manual labor. This allows us to deburr your parts faster, which translates to faster turnaround times for you.
Incodema houses three four-slide machines for precision parts forming. Our four-slides are ideal for creating small parts like electrical connectors, flat springs, brackets, clips and any parts that require intricate forming. Maintaining multiple machines on our shop floor means we can produce large runs faster than most other manufacturers.
We maintain three multi-slide machines on our shop floor. Multi-slide machines have eight axes, and they can produce smaller components with greater complexity than a four-axis four-slide machine. They are ideal for producing flat terminals, flat springs, brackets, clips and wire forms. These machines are also extremely efficient, and they can produce one part every two seconds.
Incodema houses eight press brakes with 0.0001” resolution.
This press’s large bed size of 3’ by 6’ makes it ideal for producing large parts. It’s advanced controls and versatility make it one of our most accurate and dependable machines and reduces production time.
This press provides reliable and efficient punching, and it is powerful enough to punch through the toughest materials without sacrificing quality.
We have three Electrical Discharge Machines (EDM) on our shop floor. EDM is a cutting technology which uses high electrical currents to erode metal on a workpiece. EDM creates highly detailed, very small prototype parts typically made of conductive metal, and our EDMs can cut complex contours in pre-hardened steel without the need for additional heat-treating. These machines are extremely accurate with super tight tolerance capabilities, and they are perfect for precision cut parts. We also use the EDM to cut high precision tooling for your most complex formed parts.
Developed in-house and only available at Incodema, this innovative process is similar to fully automated 4-slide and multi-slide manufacturing. This machine is ideal for low to mid-level production of parts with a material thickness of up to 0.020” and a width of 1”. It is significantly faster than manual bend press brakes and can form complex, small internal features using pre-blanked parts. With this machine, we can produce parts in minutes that take hours to form on a traditional press brake.
This machine is the fastest laser cutter on our shop floor and is the work horse of the shop. Unlike CO2 lasers, it can cut through copper.
Our Bliss Press is perfect for mid-level production and is less expensive than traditional high volume tooling. It is capable of high speed, rapid blanking and simple, progressive automated die production. With this press, we can deliver your parts in as little as 5 to 6 weeks.
Working with NYC-based design firm Factioned, Ithaca-based Incodema, Inc. built the metal portion of a beer can for Busch’s #Car2Can campaign using actual parts of Kevin Harvick’s NASCAR race car.
Working with our local hospital Cayuga Medical Center (CMC), the talented team at Incodema was called to help with COVID-19 face shields. After discussions with CMC, we realized the significant challenge is that most shields are single-use or can be cleaned only a limited numer of times before needing to discard. We created solutions to this problem and have included the open-source CAD file below for your use. Send an email to firstname.lastname@example.org for more information.
1920 Slaterville Road
Ithaca, NY 14850