Processes Used in Precision Sheet Metal Fabrication / /
Fiber Laser Cutting
Laser cutting machines make their cuts within an enclosure using no mechanical components. The enclosure decreases the risk to the machine operator while also producing less noise. Fiber laser cutting uses laser diodes transmitted through optical fibers to create desired cuts in the raw material. The fiber laser cutting method uses a high-power output and high-intensity level, making it a very efficient manufacturing process.
Waterjet Cutting
Water jet cutting uses a high-pressure pump which forces water through a nozzle to make precise cuts. The cut is facilitated by the balance of volume and velocity. To create abrasive water cuts, an abrasive substance is mixed with water. Both the water and abrasive media can be recycled and reused, which helps to increase energy efficiency while reducing costs.
Microcut™ Micro Water Jet Cutting
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 facilitates the production of tiny and complex parts.
Wire EDM
During wire EDM process, a metal piece is placed into a dielectric bath where a charged thin metal wire uses electrical sparks to melt the material and make cuts. The spark’s voltage bridges 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.
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. Stamping may involve punching, blanking, bending, drawing, embossing and more.
Forming
Sheet metal is loaded onto a flatbed where a laser cutter draws pre-programmed parts onto the material. To add additional materials to the part, a sheet metal punch may be used. The part is deburred and then moved to a press brake where it is shaped further.
Prototype Etching
Prototype etching uses photochemical machining, chemical milling, or acid etching to make a part. During prototype etching, temperature-controlled etching chemicals are used to selectively remove material. Chemical etching is ideal for prototyping because of its shorter lead time and inexpensive tooling.
Production Etching
Production etching may use photochemical machining or chemical milling to produce 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.
Laser Cutting
Laser cutting uses a high-powered laser beam is to cut the workpiece. The cutting technique may use 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.
CNC Punching
During CNC punching the raw material is moved in a 2-axis direction and positioned under a punching ram. The punching ram punches a hole or form into the workpiece. CNC punch press machines can have one head and tool rail design or a multi-turret design.
Welding
Fathom’s welding team uses heat and pressure to fuse two or more parts together. Welding services include arc welding, metal inert gas (MIG), tungsten inert gas (TIG), resistance spot welding, laser welding and oxyfuel welding and cutting.
Hardware Installation
Fathom offers hardware installation services as part of its complete sheet metal fabrication program. Whether a project a low or high volume of parts, Fathom can ensure great quality and efficiency.
Sanding/Grinding
Fathom can finish your part with sanding or grinding services. Grinding can remove weld or add any desired cosmetic surface. Sanding deburrs and removes scratches from parts after they have been punched or laser cut.
Liquid Painting
Liquid painting is used where powder coating is not suitable. Liquid painting can result in a professional finish, corrosion resistance, custom colors and more.
Powder Coating
The workpiece is covered with an even coating of powder and then cured. After the part has cured, it has a professional finish that can be matte, smooth, textured and more. Fathom has multiple powder coating finishes to choose from.
Screen Printing
Sheet metal parts can be screen printed in a variety of different finishes and colors. Fathom can also add a design of your choice to your custom part.
Assembly & Kitting
The Fathom team can perform assembly and kitting in-house. Services include hardware installation, manual or automated processes and more. Fathom will ensure your finished part meets your exact specifications.
Fathom’s laser equipment leads as the industry gold standard of laser cutting technology thanks to their incredible speed and accuracy.
Waterjet cutting machines can cut through metal and composite material with CNC accuracy and without heat affected zones. This machine tool process works by using a pressurized combination of water and abrasive material, such as garnet, forcing it through a nozzle and onto the raw material, forming the desired shape. Abrasive waterjet cutting is a suitable match for heavy gauge and tough applications as it can cut raw materials with a thickness up of up to 6 inches.
Our technicians can achieve a mirror-like finish using a finishing tool. Fathom’s finishing machine allows us to achieve great quality and a quick turnaround.
Fathom’s automated deburring system can process up to 3 metal sheets per minute without any manual labor. Parts are deburred quickly, resulting in a quick turnaround for our customers.
Fathom houses three four-slide machines for precision parts forming. Four slide machines can create small parts like electrical connectors, flat springs, brackets, clips and any parts that require intricate forming. Having multiple machines on our shop floor means we can produce large runs faster than most other manufacturers.
Fathom has three multi-slide machines with eight axes. Multi-slide machines can produce smaller components with great complexity and are great at producing flat terminals, brackets, clips and wire forms. Multi-slide machines are highly efficient and can produce one part every two seconds.
Fathom has eight press brakes with 0.0001” resolution.
The 300 Ton Press has a large bed size of 3’ by 6’, which makes it ideal for producing larger parts. It has advanced controls and versatility, which make it one of our most accurate and dependable machines that help to reduce production time.
The 22 Ton Press provides reliable and efficient punching. It is powerful enough to punch through tough materials while maintaining quality.
Fathom utilizes three Electrical Discharge Machines (EDM). Electrical discharge machining is a cutting process that uses high electrical currents to erode metal on a workpiece. EDM can result in highly detailed, very small prototype parts typically made of conductive metal. Fathom’s EDM machines can cut complex contours in pre-hardened steel without the need for additional heat treatments. EDM machines are 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.
Only available through Fathom, the seely slide machine was developed in-house. The seely slide forming tool is like a fully automated 4-slide and multi-slide manufacturing. The process is ideal for low-to-mid level production jobs with material thickness of up to 0.020” and a width of 1”. Using a seely slide forming tool is faster than manual bend press brakes and can be used to form complex, small internal features using pre-blanked parts.
Fathom’s Bliss Press is ideal for mid-level production and is less expensive than tradition high-volume tooling. The bliss press is capable of high speed, rapid blanking and simple, progressive automated die production. Using this press, we can deliver parts in as little as 5 to 6 weeks.