Fathom delivers high-quality parts to its customers by using sheet metal fabrication technology. Whether your project is time-sensitive, high-precision, highly complex or short production run related, Fathom will meet your requirements. Get your metal fabrication quote today.
When calculating the cost of a custom sheet metal job, consider the design, material, quantity ordered and turnaround time. Custom sheet metal projects that call for complex geometric and intricate shapes with a high level of accuracy are possible. Certain sheet metal fabrication methods such as wire EDM make little to no contact with the raw material, making it possible to cut very precise intricate features. Quotes are typically categorized based upon whether an item is flat, formed, or drawn. The type of material selected is also factored into the cost of sheet metal fabrication. Common materials for sheet fabrication include both ferrous and non ferrous metals e.g. steel, aluminum, stainless steel, brass, copper, bronze and others. The quantity ordered plays a large role in determining the most efficient manufacturing process. To reduce costs, there are several strategies that can be employed i.e. stacking parts during cutting reduces overall time on machine saving you money. Lastly, the turnaround time can influence cost. To help save time and money, Fathom offers an all-in-one program for metal fabrication. Our team can fulfill every customer need throughout the sheet metal fabrication process from design to fabrication to finishing and assembly.
During fiber laser cutting, laser cutting machines create cuts within an enclosure using no mechanical components. The enclosure minimizes the risk to the machine operator while also reducing noise. Fiber laser cutting uses a high-power output and high-intensity laser, making it a very efficient manufacturing process.
To make precise cutes, water jet cutting uses a high-pressure pump which forces water through a nozzle. The cut is facilitated by the balance of volume and velocity. For cuts that require an abrasive waterjet, abrasive media is combined with water. Both the water and abrasive media can be recycled and reused, which helps to increase energy efficiency while reducing costs.
Micro water jet cutting uses the manufacturing capabilities of water jet cutting to produce parts on a micro-level. Water jet cutting’s high-level of accuracy is what allows to produce tiny and complex parts.
The wire EDM process submerges a metal piece into a dielectric liquid where a charged thin metal wire uses electrical sparks to melt the material and make cuts. The spark’s voltage jumps the gap from the wire to the workpiece which causes the material to melt. The metal wire never contacts the workpiece. The dielectric fluid controls the sparks, cools and flushes away excess material.
During stamping, a blanked or coiled piece of sheet metal is placed in a press where the stamping tool is pressed onto the material. The stamping tool or die contains the desired shape of the part. Punching, blanking, bending, drawing and embossing are all stamping techniques.
To form a part, sheet metal is loaded on a flatbed where a pre-programmed design is drawn onto the material using a laser cutter. To add more features, a sheet metal punch can used. The part is then deburred and moved to a press brake for further shaping.
Methods of prototype etching include chemical milling or acid etching. During photochemical machining, material is selectively removed by using baths of temperature-controlled etching chemicals. Chemical etching is ideal for prototyping because of its shorter lead time and inexpensive tooling.
Production etching uses photochemical machining or chemical milling to make parts with high precision and intricacies. Production etching is perfect for transitioning prototypes into production because it is fast, cost-effective and offers great design flexibility.
A high-powered laser beam is used to cut raw material during laser cutting. Techniques may include a gas, liquid or solid-state laser. CO2 lasers use a gas state laser using a mixture of carbon dioxide to make cuts. Solid state lasers use laser diodes transmitted through optical fibers to create cuts.
In a CNC punching machine, raw material is moved along a 2-axis direction and positioned under a punching ram. The punching ram adds holes and/or forms to the sheet metal. CNC punch press machines can have one head or a multi-turret design
Welding fuses two or more parts together using heat and pressure. Arc welding, metal inert gas (MIG), tungsten inert gas (TIG), resistance spot welding, laser welding, oxyfuel welding and cutting are all offered by Fathom.
Fathom offers hardware installation services. Whether a project contains a low or high volume of parts, Fathom can ensure great quality and efficiency.
Fathom has sanding and grinding services. Typically grinding is utilized to remove weld fillets it can also be used to add a desired cosmetic surface or pattern. Sanding deburrs and removes scratches from parts after they have been punched or laser cut.
Liquid painting is used when powder coating is not possible. Liquid painting offers can result in a professional finish, corrosion resistance, custom colors and more.
During powder coating, the workpiece is covered with a uniform coating of powder and then cured. Once the part has dried, it has a professional finish. That may be matte, smooth, textured and more. Fathom has a wide range of powder coating finishes to choose from.
Screen printing adds a variety of different finishes and colors to a part. Fathom can also add a custom design of your choice.
Assembly and kitting can be performed in-house by the Fathom team. Services include hardware installation, manual or automated processes and more. Fathom will ensure your finished part meets your exact specifications.
Fathom has strategic partnerships and with key suppliers of heat treating, plating and powder coating who meet our standards for both quality and speed. As part of the Fathom Manufacturing Platform, Fathom has access to a robust nationwide network of comprehensive additive and advanced manufacturing. Fathom Manufacturing’s extensive certifications include ISO 9001:2015, ISO 9001:2015 Design, ISO 13485:2016, AS9100:2016, NIST 800-171 and ITAR.
Once a part has been fabricated, it can occasionally require post CNC machining. Fathom has in-house CNC machining centers that can add post-mill features to sheet metal parts, allowing us to successfully manufacture parts within time constraints.
Fathom’s team of engineers and master tool makers can deliver creative tooling solutions for your formed parts. We specialize in complex bending and precision and are not intimidated by challenging design features. Our capabilities include intricate EDM tooling, waterjet cut tools and robust CNC machined tooling.
Attention to detail is critical in the manufacturing process. Our services include deburring and finishing to remove laser dross, mechanical burrs, harps or other surface imperfections. Other finishing processes include hand sanding, automated deburring, tumbling and more.
Fathom is ready to deliver on your sheet fabrication needs. Laser cutting, water jet cutting, Microcut™ and photochemical machining are just a few of the services offered by Fathom. Fathom can finish your project from design to finishing all in-house. Fathom offers post-processing services such as welding, deburring, bead blasting and more. Sheet metal prototyping is just one of 28 manufacturing services offered by Fathom.
Standard lead times are below, but 24hr expedite options are available.
| Parts | Delivery time |
|---|---|
| 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 |
Fathom’s manufacturing network is powered by over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Fathom’s has equipment dedicated to metal fabrication, including lasers, waterjet machines, finishing tools, auto deburring, 4 slide machines, multi-slide machines, press brakes, 300-ton presses, 22-ton presses, wire EDM machines, seely slide forming tools and 35-ton blanking presses.
Fathom offers both metal fabrication and hybridized services that leverage metal fabrication. Do you need metal fabrications as part of a more complex job? Fathom can help. A recent case study is listed below where Fathom delivered 20,000 parts in 27 days using 55+ tools, including metal prototype fabrication services:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
Fathom offers nationwide coverage to the entire United States, including 3 US-based manufacturing facilities with metal fabrication services. Fathom’s advanced prototyping and manufacturing services include injection molding, CNC machining, chemical etching, metal 3D printing, and more. We have provided over 200,000 quotes to leading US companies and are ready to provide you with a quote today.
Locations include:
COLORADO
7770 Washington Street
Denver, CO 80229
ISO 9001:2015
ITAR
NEW YORK
1920 Slaterville Road
Ithaca, NY 14850
ITAR
401 W. Shore Boulevard
Newark, NY 14513
ISO 9001:2015
AS910:2016
ITAR
Need precision forming? Fathom has developed a technique which transforms an ordinary press brake into a manual progressive die. We can easily meet intricate and complex design specifications by combining this dynamic technique with our custom tooling made in-house by our toolmakers.
Fathom can manufacture both small, complex and larger parts in-house. Our manufacturing facility in Ithaca, New York houses a 300 Ton Press with a 36” x 72” bed. This 300 Ton Press is ideal for small volume projects that call for deep-drawn custom parts or large die sets with embosses and gussets.
Looking for more volume? Our services include mid to high volume solutions that take advantage of lower tooling and setup costs when compared to progressive die manufacturing and can include custom features such as gussets and embosses. All tooling is designed and built in-house, making Fathom a comprehensive manufacturing supplier.
For mid-to-high volume quantities, we offer various cost-effective and semi-automated tooling solutions at 15-30% of the cost of fully automated production tooling.
Small and intricate springs, brackets, electrical terminals, clips and battery contacts can all be made in high volume quantities using four slide and multi-slide manufacturing. All tooling is designed and built in-house by our team of experts.
Our experienced tool makers design and create complex tooling solutions to meet the requirements of even the most challenging stamped parts. Our team of hands-on operators also possess engineering skills that allow them to come up with creative manufacturing solutions on the fly and keep the production process progressing forward.
Before the manufacturing process can begin, you will need to estimate the cost. Cost can be greatly influenced by the design of a metal part. For example, if a part requires multiple sheet metal fabrication machines or processes, the cost can increase. Most sheet metal parts do require more than one fabrication method to achieve the desired results. Fathom offers a hybridized approach to manufacturing, which means our team can leverage our sheet metal fabrication processes in addition to any of our other 28 manufacturing services.
A: Yes, Fathom offers metal prototype fabrication.
A: Metal prototype manufacturing is creating a sample or “rough draft” part that can be used to test the form and function before mass production.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Fathom offers sheet metal fabrication services with a 24 hour expedite option.
A: The cost of metal fabrication depends on the material selected, complexity of design, quantity ordered and turnaround time.
A: Submit your file through Fathom’s SmartQuote platform and receive a quote within as little as 1 hour, usually within 24 hours.
A: The cost of both metal fabrication and 3D printing largely depends on the material selected, complexity of design, quantity ordered and turnaround time.
Are you ready to calculate costs or receive a quote on your next metal fabrication project? Use Fathom’s SmartQuote application for a quick quote.
