Fathom is a sheet metal company delivering high-quality parts to its customers. Our team can meet the requirements of your time-sensitive, high-precision, highly complex or short production related projects.
Sheet metal companies offer innovative manufacturing solutions to a variety of industries including electronics, aerospace, defense and more. Sheet metal can be used to produce prototypes, chassis, appliances, medical equipment, and brackets, just to name a few. Sheet metal is a widely available raw material made from different metals including steel, aluminum, magnesium, copper or brass. Sheet metal companies offer forming, cutting, and joining and provide services such as laser cutting, water jet cutting, chemical etching and more.
Fiber laser cutting is an efficient manufacturing process that uses a high-power output and high-intensity level. 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. It also offers increased efficiency, accuracy and a lesser heat effected area than traditional CO2 lasers.
Water jet cutting is used when a project calls for flat parts, custom tooling and blanking parts that will be formed later in the manufacturing process. Water jet cutting utilizes a high-pressure pump which forces water through a nozzle to make precise cuts. The cut is facilitated a balance of volume and velocity. To make abrasive water cuts, a garnet or other abrasive substance is combined with water.
Micro water jet cutting is the production of complex, tiny parts. Water jet cutting’s high level of accuracy is what facilitates the manufacturing of parts on a micro level. Microcut is a very unique technology that is is not widely available. So if your project could benefit from our Microcut technology, reach out to get a quote.
Wire EDM uses electrical currents to cut raw material. The cuts are made when the metal piece is submerged in a dielectric liquid where an electrically charged thin metal wire uses electrical sparks to melt the material. The spark’s voltage jumps the gap from the wire to the workpiece which creates the cut. The metal wire never contacts the workpiece. The fluid is used to cool, flush excess material, and control the spark.
Punching, blanking, bending, drawing and embossing, are just of the few of the processes used in stamping. During stamping, a blanked or coiled slit to width sheet metal is loaded in a press where the stamping tool strikes/stamps the material. The stamping tool or die contains the desired shape of the part.
Prototype etching may use photochemical machining, chemical milling or acid etching to make a part. Chemical etching offers a shorter lead time and inexpensive tooling, which make it an ideal process for prototyping. Material is selectively removed by using baths of temperature-controlled etching chemicals.
Production etching uses photochemical machining or chemical milling to make metal parts with high precision and intricacies. Production etching is perfect for transitioning prototypes into production because it offers a rapid turnaround, is cost-effective and has great design flexibility.
CNC punching uses a punch press machine that moves raw material in a 2-axis direction, positioning the workpiece 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.
To weld, a combination of heat and pressure are used to join two or more pieces together. Welding services include arc welding, metal inert gas (MIG), tungsten inert gas (TIG), resistance spot welding, laser welding and oxyfuel welding and cutting. Spotwelding may also be used, which uses copper alloy electrodes to direct a welding current.
Fathom offers a complete sheet metal fabrication program, including hardware installation services. Our team can ensure efficiency and great quality for low- and high- volume production.
Fathom offers sanding and grinding services. Grinding removes weld or adds any desired cosmetic surface. Sanding removes scratches or burrs from parts after laser cutting or punching.
Liquid painting is a good match for projects that cannot use powder coating. The resulting finish can be corrosion resistant, custom colored and more.
When a metal workpiece is powder coated, it is covered in a uniform powder that is cured. The result of powder coating is a professional grade finish that may be smooth, textured, matte and more. Fathom offers a variety of different powder coating options.
Screen printing can be used to add a custom design to a part. Screen printing can result in various finishes and colors.
Fathom offers in-house assembly and kitting. Services include installing hardware, manual or automated process, and more. Fathom will ensure your finished part is to your exact specifications.
Fathom has a wide range of sheet metal fabrication services to meet the requirements of your next project. Our manufacturing services include laser cutting, water jet cutting, Microcut™, photochemical machining and wire EDM. Finishing and post-processing services available include welding, deburring, bead blasting, and more. Sheet metal prototyping is just one of 28 manufacturing services offered by Fathom.
To meet the needs of our customers, Fathom utilizes over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Fathom’s has equipment dedicated to metal prototype 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’s services are not limited to sheet metal fabrication and include hybridized services leveraging sheet metal fabrication. Need sheet metal fabrication as part of a more 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’s nationwide network includes 3 US-based locations for sheet metal fabrication.
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
Sheet metal cutting can be used for both prototyping and production. Sheet metal fabrication is often favored by engineers for its high level of precision. Tolerances up to 0.0005” are possible depending on the manufacturing process. Additional factors that affect tolerance include the complexity of design, geometry and raw material.
| 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
To improve on existing precision forming methods, Fathom has developed a technique in which a press brake is used as a manual progressive die. Combined with the custom tooling produced by our in-house toolmakers, we can deliver intricate and complex parts.
Fathom’s Ithaca, New York location has a 300 Ton Press with 36” x 72” bed, perfect for projects that are too large for a traditional press brake. The 300 Ton Press is best for smaller volume jobs with deep-drawn custom parts or for large die sets with gussets and embosses.
Fathom offers mid to high volume production solutions. Benefits include lower tooling and setup costs than progressive die manufacturing and can include custom features like gussets and embosses. All tooling is custom made in-house, making Fathom a turnkey manufacturing supplier.
For mid to high volume quantities, Fathom offers cost-effective, semi-automated tooling solutions that cost 15-30% of fully automated production tooling.
High volume quantities of small and intricate springs, brackets, electrical terminals, clips and battery contacts can be made using four and multi-slide manufacturing. Tooling is designed and built in-house by our team of experts.
Fathom employs skilled and creative toolmakers to design and manufacture complex tooling solutions needed to make even the most challenging stamped parts. Fathom’s hands-on operators possess engineering skills and are empowered to deliver manufacturing solutions on the fly to keep the manufacturing process moving forward.
No matter what industry, our team can meet the technological and manufacturing challenges your project demands. Fathom has provided sheet metal services for the Medical, defense, aerospace, electronics, automotive and industrial industries.
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 is capable of a same day turnaround for sheet metal parts.
A: Sheet metal prototyping is the use of sheet metal manufacturing methods to produce prototypes. Manufacturing methods may include water jet cutting, chemical etching, wire EDM and more.
A: Sheet metal modeling is the digital process of designing a sheet metal part.
A: Three methods of shaping sheet metal include bending, cutting, and shrinking. Bending sheet metal is accomplished using a metal brake, cutting may be done manually using hand shears or snips and shrinking uses heat which is applied to an overstretched area.
A: When designing for sheet metal manufacturing in CAD, the thickness of the material, bend radius, and k-factor must all be considered.
Need a sheet metal fabrication quote? Are you ready to calculate costs for your next project? Submit your file today on Fathom’s SmartQuote application for a fast quote.
Precision manufacturing
from coast to coast.
HEADQUARTERS //
1050 Walnut Ridge Drive
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
