Fathom delivers high quality parts to its customers by using rapid sheet metal manufacturing technology. Whether your project is time-sensitive, high-precision, highly complex or short production run related, Fathom will meet your requirements and deadlines.
Using a rapid sheet metal prototype offers many benefits. A prototype can be used as a physical example of a product, making it easier to explain the features and benefits to investors or customers. The model can also be used for the creation of marketing assets, like instruction manuals or ads. Functional prototypes test a design’s form, fit, and function, ensuring the end product works as intended. Being able to test a concept prior to mass production lowers the overall cost by gathering feedback and making necessary changes before a part is made large quantities.
Fiber laser cutting uses laser diodes transmitted through optical fibers to create desired cuts. Laser cutting machines make their cuts within an enclosure using no mechanical components. The process makes less noise while decreasing any personal risk to the machine operator. Fiber laser cutting uses a high-power output and high-intensity level, making it a very efficient manufacturing process.
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.
Micro water jet cutting uses the manufacturing capabilities of water jet cutting to produce parts on a micro-level. MicroCut’s high-level of accuracy is what facilitates the production of tiny and complex parts.
The wire EDM process submerges a metal piece into a de-ionized water (dielectric) where a charged thin metal wire uses electrical sparks to melt the material and create 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 is used to control the sparks, cool and flush away excess material.
During stamping, a blanked or coiled piece of sheet metal is loaded 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.
The 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 may use photochemical machining, chemical milling or acid etching to make a part. 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.
Like prototype etching, production etching uses photochemical machining or chemical milling to create metal 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 uses a high-powered laser beam to cut material. A gas, liquid, or solid-state laser cutting technique may be used. 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.
Computer numerically controlled punching uses a machine that moves metal in a 2-axis direction and positions the raw material beneath a punching ram. The punching ram punches a hole or form in the sheet metal. CNC punch press machines can have one head and tool rail design or a multi-turret design.
Fathom is ready to work on your rapid sheet metal prototype. Our services include laser cutting, water jet cutting, Microcut™, photochemical machining and wire EDM. Finishing and post-processing services are also available including welding, deburring, bead blasting, and more. Rapid 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 |
With over 530 machines, Fathom’s manufacturing facilities include mills, lathes, presses, press brakes, turret punches and additive systems. Fathom has equipment dedicated to rapid sheet metal prototype fabrication, including lasers, waterjet machines, finishing tools, autodeburring, 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 not just rapid sheet metal prototype fabrication but also hybridized services leveraging prototype fabrication. Do you need a rapid sheet metal prototype for your complex project? Fathom can handle it. 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 is a nationwide network with coverage across the entire United States, including 3 US based locations producing rapid sheet metal parts. Our 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
Rapid sheet metal fabrication is a good match for low to high volume projects. Fathom’s rapid sheet metal technology has tolerances of up to 0.0005” depending on the production method used. Geometry, complexity of design and raw materials selected also affect tolerance.
| 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 75% of material thickness. Outer Radius should be material thickness plus Inside bend radius.
**Dependent on geometry, volume and material: 24hr Expedite options available
There are multiple factors to consider when selecting material for your rapid sheet metal part. Matching your project with a material that is durable and efficient is critical. When picking the best raw material, you should also consider how the part is intended to perform. Size and geometry are also important. Lastly, consider any finishing that will be needed to meet the project’s specifications.
For projects that call for stiffness and spring characteristics, there are several factors the design engineer should consider. Parts with small radius forms, high carbon spring steel or another heat treatable metal with good ductility should be used. The part may still require heat treating after forming to achieve stiffness or spring performance characteristics, which adds to the cost of manufacturing. It is important to note that broad flat sections in parts made from high carbon spring steel will warp during heat treating. Where potential warping may be a factor, other alternate materials with a marginally higher cost that maintain stability during heat treating should be considered.
A mill-hardened alloy may be used for flat parts or parts with large radius form features. The mill hardened alloy may be selected based on hardness or spring performance characteristics, eliminating the need for heat treating.
Consider the following:
Fathom’s welding team uses a combination of 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.
Fathom offers hardware installation services as part of its complete sheet metal fabricating program. We can ensure efficiency and great quality for both low and high-volume production runs.
Sanding and grinding services are both offered by Fathom. Grinding removes weld or adds any desired cosmetic surface. Sanding can remove scratches or burrs from parts after laser cutting or punching.
Liquid painting is a finishing process suitable for projects where powder coating cannot be used. Liquid painting can result in a professional finish, corrosion resistance, custom colors and more.
During powder coating, a sheet metal part is coated in a powder which is then cured. The resulting professional finish may be matte, smooth, textured and more. Fathom offers a variety of different powder coating finishes.
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.
Our team can perform assembly and kitting in-house. Services include installing hardware, manual or automated process, and more. Fathom will ensure your finished part is to your exact specifications.
Fathom maintains strategic partnerships that benefit our customers, including key suppliers of heat treating, plating, and powder coating. Our partners were chosen because they can meet our high quality and speed requirements. As part of the Fathom Manufacturing Platform, Fathom has access to a robust nationwide network of comprehensive additive and advanced manufacturing capabilities. Fathom Manufacturing’s extensive certifications include ISO 9001:2015, ISO 9001:2015 Design, ISO 13485:2016, AS9100:2016, NIST 800-171 and ITAR.
Occasionally post CNC machining is required to finish a part. Fathom’s CNC machining centers provide post-mill features on sheet metal components, allowing us to successfully manufacture parts while meeting tight deadlines.
Fathom’s team of engineers and master tool makers can develop creative tooling solutions for your quick turn sheet metal parts. We specialize in complex bending and precision and look forward to solving your most challenging design features.
Fathom understands that attention to detail is critical to manufacturing. 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.
Many parts are made using rapid sheet metal technology. Fathom understands the demand for rapid sheet metal services that lower cost and meet deadlines. In some cases, no machining or tooling is needed. By leveraging automated production techniques, Fathom can produce parts quickly and accurately. Some applications of rapid sheet metal manufacturing include:
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 has 24 hour expedite services.
A: Rapid production is the quick turnaround of parts.
A: The most used rapid prototyping method is 3D printing.
A: Rapid prototyping is necessary because it allows designers to test a concept before moving to full production, allows engineers to look for design flaws, and helps a marketing team to showcase a physical sample while seeking investors.
A: Rapid prototyping is different from 3D printing. Rapid prototyping is a broad term that includes manufacturing methods use to create a prototype within a short timeframe. 3D printing includes a wide range of manufacturing methods that may/may not be used to create a prototype.
A: The three types of materials used in rapid prototyping include solid sheets, powder-based and molten material.
Are you ready for a quote on your rapid sheet metal project? Do you want to calculate costs on your design? Use Fathom’s SmartQuote application for a fast quote.
Precision manufacturing
from coast to coast.
HEADQUARTERS //
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Hartland, WI 53029
877-328-4668
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
480-966-2300
CALIFORNIA
46758 Lakeview Blvd
Fremont, CA 94538
COLORADO
7770 Washington St.
Denver, CO 80229
303-288-6855
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
815-385-7500
1401 Brummel Ave
Elk Grove, IL 60007
847-952-8088
MINNESOTA
13758 Johnson Street NE
Ham Lake, MN 55304
763-755-7575
NEW YORK
1920 Slaterville Rd.
Ithaca, NY 14850
607-277-7070
401 W. Shore Blvd.
Newark, NY 14513
315-331-7680
TEXAS
1513 Sam Bass Rd.
Round Rock, TX 78660
512-255-1477
