Fathom is hiring for multiple positions across our 12 nationwide sites! To see all open positions, click here.

logo fathom

Sheet Metal Companies

  • Highly Durable Metal Parts
  • Precise Components with Tight Tolerances
  • Variety of Metals & Alloys with Unique Properties
Over 200,000 quotes provided to top US companies.
Comprehensive
Sheet Metal Fabrication Services
Highly Scalable
with Versatile Materials
customer specs icon
Manufactured to
Customer Specs
printer icon
Comprehensive Access to
Equipment & Experience
Sheet Metal Companies

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.

What Do Sheet Metal Companies Do? / /

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.

Services That Sheet Metal Companies Offer / /

Fiber Laser Cutting

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

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.

Microcut™ Micro Water Jet Cutting

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

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.

Stamping

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

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

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

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.

Welding

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.

Hardware Installation

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.

Sanding/Grinding

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

Liquid painting is a good match for projects that cannot use powder coating. The resulting finish can be corrosion resistant, custom colored and more.

Powder Coating

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

Screen printing can be used to add a custom design to a part. Screen printing can result in various finishes and colors.

Assembly & Kitting

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.

Sheet Metal Company Services Offered by Fathom / /

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.

Additive Manufacturing

  • FDM
  • SLS
  • SLA
  • Polyjet
  • MJF
  • DMLS
  • DLS
  • STEP (Evolve)

CNC Machining

  • CNC (3 & 5 Axis)
  • CNC Lathe
  • Precision Grinding
  • Wire & Sinker EDM

Injection Molding

  • Injection Molding
  • Tooling
  • Compression Molding

Metal Cutting and Forming

  • Thermoforming
  • Sheet Metal Punching
  • Sheet Metal Cutting
  • Metal Forming
  • Laser Cutting
  • Water Jet Cutting
  • Chemical Etching
  • Welding
  • Micro Cutting

Standalone

  • Die Casting
  • Urethane Casting
  • Composite Layups
  • Extrusion
  • Post Processing & Finishing
    • Pad Printing
    • Powder Coating
    • Bead Blasting
    • Surface Grinding
    • Polishing
    • Anodize
    • Powder Coat Passivate
    • Chemfilm
    • Vacuum Metallization
    • Silkscreen
    • Plating
    • Tumbled

Sheet Metal Machines Used 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:

Case Study //

Real Customers. Real Results.

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.

20,000 Parts // Within 27 Days
55+ Tools to Injection Mold 15,000 Parts First Article in 2 Weeks
15,000

55+ Tools to Injection
Mold 15,000 Parts

First Article in 2 Weeks

3,000+ 3D Printed Parts
3,000

3,000+ 3D
Printed Parts

2,000+ Metal Fabricated Parts
2,000

2,000+ Metal
Fabricated Parts

Hybridized Services Used //

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 Locations for Sheet Metal Services / /

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 Prototyping Cutting Specifications and Tolerances / /

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

Precision Forming: Prototype to Low-Volume / /

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.

Large Format Parts and Prototypes / /

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.

Large format parts and prototypes

Mid to High Volume Production / /

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.

Semi Automated Manufacturing

For mid to high volume quantities, Fathom offers cost-effective, semi-automated tooling solutions that cost 15-30% of fully automated production tooling.

  • Photo Chemical Machined Flat Blanks: Produce small, thin parts with complex flat geometry that are made burr free and ready for forming.
  • Put-and-Take Tooling – Semi-complex dies made manually or by machine, form complex features and/or multiple bending operations in one step.
  • Die Blanking – Flat parts and some parts with formed features may be manufactured completely by full automation or made ready for secondary, semi-automated bending and forming processes.

Four-Slide and Multi-Slide

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.

Specialty Stamping

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.

Sheet Metal Applications by Industry / /

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.

  • Aerospace: Aerospace parts must meet standards that call for high accuracy and tolerances. Our team can deliver parts for the aerospace industry that are both durable and reliable.
  • Automotive: The automotive industry has rigorous standards and every finished part that departs our facilities will meet those requirements. You can rely on Fathom for sheet metal parts that are both reliable and safe.
  • Defense: The defense industry requires high precision, confidentiality, and efficiency. Fathom is an ITAR registered manufacturer, ready to support all military and homeland security projects including weapons, vehicles and more.
  • Electronics: The electronics industry requires parts with tighter tolerances and finer surfaces. Whether your electronics project needs a simple or complex design, Fathom can deliver.
  • Industrial: Industrial parts must be reliable and durable. Using our all-in-one manufacturing services, we can assist you from design to finishing of your on-demand part.
  • Life Sciences: The medical industry sets high standards for both quality and cleanliness.

Sheet metal prototyping FAQs / /

Q: Does Fathom offer metal prototype fabrication?

A: Yes, Fathom offers metal prototype fabrication.

Q: What is 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.

Q: Is Fathom ISO certified?

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.

Q: Is Fathom ITAR certified?

A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Is Fathom AS9100:2016 certified?

A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Is Fathom NIST 800-171 certified?

A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Can Fathom offer same day sheet metal?

A: Fathom is capable of a same day turnaround for sheet metal parts.

Q: What is sheet metal prototyping?

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.

Q: What is sheet metal modeling?

A: Sheet metal modeling is the digital process of designing a sheet metal part.

Q: What are the three methods of shaping sheet metal?

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.

Q: How do you design sheet metal?

A: When designing for sheet metal manufacturing in CAD, the thickness of the material, bend radius, and k-factor must all be considered.

How to Get Sheet Metal Fabrication Quotes / /

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.

Manufacturing Locations Across National Time Zones
Manufacturing Locations Across National Time Zones
The Fathom Advanced Manufacturing Platform
new map update 3
HEADQUARTERS

1050 Walnut Ridge Drive
Hartland, WI 53029
ISO 9001:2015
AS9100:2016
ITAR

ARIZONA

444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST800-171 Compliant
ITAR

COLORADO

7770 Washington St.
Denver, CO 80229
ISO 9001:2015
ITAR

MINNESOTA

13758 Johnson Street NE
Ham Lake, MN 55304

TEXAS

1801 Rowe Lane
Pflugerville, TX 78660
ISO 9001:2015
AS9100:2016

1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016

CALIFORNIA

620 3rd Street
Oakland, CA 94607
ISO 9001:2015 Design Certified
NIST 800-171 Compliant
ITAR

FLORIDA

14000 N.W. 58th Court
Miami Lakes, FL 33014

NEW YORK

1920 Slaterville Rd
Ithaca, NY 14850
ITAR

401 W. Shore Blvd.
Newark, NY 14513
AS9100:2016
ISO 9001:2015
ITAR

ILLINOIS

1207 Adams Drive
McHenry, IL 60051
ISO 9001:2015

1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified

fathom yellow color logo