Sheet Metal Fabrication
- Extensive Capabilities from Prototype to Production
- Decades of Sheet Metal Fabrication Expertise
- Simplify Your Supply Chain
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Comprehensive Sheet Metal Fabrication
An eye on value-engineering your projects with Fathom
Simplify Your Supply Chain
Are you looking for a sheet metal fabricator who can handle everything from new product development and prototype parts to high-volume production and finishing services? Fathom is a cut above what you’ve come to expect. Our comprehensive services can help you simplify your supply chain and accelerate your time to market.
We bring a value engineering approach to every project. We’ll design a manufacturing process that ensures your parts can be produced cost-effectively and quickly. Our experts will manage every step of the process. You’re in good hands, from design assistance and metal fabrication to painting, screen printing, kitting and assembly.
- How Does Sheet Metal Fabrication Work?
- Capabilities // Cutting
- Capabilities // Forming
- Capabilities // Welding
- Sheet Metal Fabrication Materials
- Sheet Metal Fabrication Industry Applications
- What Does Sheet Metal Fabrication Make Possible?
- Sheet Metal Fabrication Case Study
- Sheet Metal Fabrication Post-Processing & Finishing
- Why Choose Fathom’s Sheet Metal Fabrication?
How Does Sheet Metal Fabrication Work?
Sheet metal fabrication is the process of cutting, bending, punching and welding flat metal sheets into shapes to create functional parts. We use specialized equipment to cut, bend, roll, form and assemble sheet metal parts into finished products.
We produce metal parts in a variety of sizes, from tiny, complex brackets to large panels and doors. We work with a variety of materials, from aluminum and stainless steel to exotic alloys. What do these components have in common? They start out as flat metal pieces.
Sheet Metal // Cutting
CNC Punching
We use punch presses to cut holes in sheet metal, either manually or under CNC control. We also use them to produce special features like countersinks, beads and louvers.
Laser Cutting
Laser cutting is one of several technologies we use for cutting sheet metal. It uses a CNC-controlled, high-powered laser to cut, engrave or mark material. The kerf width is barely wider than the laser beam. That’s why we use it to cut fine details and complex shapes. The cut is so clean that little or no post-processing is needed.
We use stand-alone laser cutters to produce prototype parts. We can also pair them with automated loading and unloading systems for medium- to high-volume production jobs.
Water Jet Cutting
Water jet cutting uses a high-pressure stream of water to cut a thin line in sheet metal. A CNC controller guides the cutting head for excellent repeatability. Water jet cutting doesn’t cause heat-affected areas. It creates clean, burr-free cuts. Little or no finishing is needed.
Water jet cutting can cut holes, complex shapes and sharp corners. Thanks to the large work envelope of these machines, Fathom’s water jet cutting service is ideal for cutting larger or multi-part projects.
Microcut™ Cutting
Microcut™ micro water jet cutting has a smaller kerf width than water jets. It can cut flat parts in thicknesses ranging from 0.001″ to 0.125″. It can cut features with tolerances up to .0005″ with incredible accuracy. It produces finished pieces with no burrs, no deformations or discolorations and no heat-affected zones. Micro water jet cutting is especially valuable for parts that require precise blanks with high tolerances that are bent into complex shapes.
Fathom Ithaca recently acquired a micro waterjet cutting machine with even tighter tolerances – as small as 10 microns (0.0008 inch).
Wire EDM
Wire EDM is a unique technology for cutting sheet metal. It cuts conductive metals with a thin electrode that follows a CNC-controlled path. The wire carries a high-voltage charge. It generates a spark that melts the material adjacent to the wire, making a very precise cut in it. A dielectric liquid cools the metal and flushes away melted particles. That also helps to minimize heat-affected areas.
Metal can be rough cut using wire EDM to a tolerance of .002 in. With trim passes, tolerance can be increased to .0002 in.
Photo Chemical Etching
Photo Chemical Etching is also known as industrial chemical etching or chemical milling. We use films, masks and etchants to create complex shapes like fine screens and filters, flat washers and shims and electrical contacts.
Because photo chemical etching doesn’t rely on heat or mechanical force, it produces parts without burrs and distortion. This makes it perfect for applications like aerospace, electrical components and hydraulics.
Sheet Metal // Forming
Press Brakes
Press brakes create sharp bends and angles in sheet metal. They can also be used to form complex shapes.
At Fathom Ithaca, we have developed a technique that converts a press brake into a manual progressive die. By combining this dynamic technique with our custom tooling, we can create intricate and complex designs.
Specialty Stamping
Our skilled and creative toolmakers design and create complex tooling solutions that enable us to manufacture even the most challenging stamped parts.
Custom Tooling
Our sheet metal fabrication experts have decades of experience. Our engineers and master tool makers can develop creative tooling solutions for your formed parts.
Sheet Metal // Welding
MIG / TIG Welding
MIG welding uses a solid wire that is machine-fed to the weld area. TIG welding uses a non-consumable electrode and a hand-held filler rod to form the weld. We offer automated and manual welding, depending upon project needs.
Spot Welding
During assembly, spot welding uses pressure and heat from an electric current to join two or more metal sheets.
Materials Available
We primarily produce sheet metal components from aluminum, stainless steel and steel alloys. We have also worked with brass and bronze. We can procure other types of sheet metal on request.
Industry Applications
Many industries choose Fathom for its sheet metal fabrication services, including medical, defense, aerospace, electronics, automotive and industrial companies. No matter what the industry, our team can meet the technological and manufacturing challenges your project demands.
Aerospace // Aerospace parts often require high accuracy and tight tolerances. Our team delivers parts for the aerospace industry that are durable, reliable and meet exacting specifications.
Automotive // Every finished part that departs our facilities will meet the rigorous standards of the automotive industry. You can rely on Fathom for sheet metal parts that are both reliable and safe.
Defense // The defense industry requires high precision and efficiency standards for weapons, vehicles, and more. Fathom is an ITAR registered manufacturer and defense contract supplier who can support all your military and defense needs for sheet metal components.
Electronics // The electronics industry requires parts with tighter tolerances and finer surfaces. Whether your electronics project needs a simple or complex design, Fathom delivers.
Industrial // Parts for industrial applications must be reliable and durable. Using our all-in-one manufacturing services, we can assist you from design to finishing your sheet metal parts.
Life Sciences // The medical industry sets high standards for both quality and cleanliness. Sheet metal fabrication is used to make a variety of medical devices.
What Does Sheet Metal Fabrication Make Possible?
Sheet metal is inexpensive compared to other materials. It’s easy to work with and enables us to produce large quantities of precision-cut and formed parts quickly and affordably. It’s a cost-effective solution to build complex parts.
Advantages
Customization // Because sheet metal is easy to work with, we can build custom metal parts that meet your precise requirements.
Affordable // Compared to machining, sheet metal fabrication is much less expensive and provides flexibility during each step of the fabrication process.
Accurate // Metal parts are cut to precise sizes and shapes using computer-controlled equipment. This minimizes the need for secondary processes such as grinding and polishing.
Scalability // Sheet metal forming accommodates production changes without big investments in retooling. This makes it well-suited for creating prototypes and small batches of parts for testing and validation. It’s also a cost-effective way to produce production parts in small to medium-sized quantities.
Short Lead Times // Sheet metal fabrication doesn’t require many processing steps. That’s why its lead time is often shorter than other manufacturing technologies. This makes it a popular option for sheet metal prototyping.
Aesthetic Appeal // Sheet metal offers multiple finishing options that we use to enhance its appearance and protect it from corrosion. They include painting, powder coating and anodizing.
Disadvantages
Overhead Costs // Many metals require additional finishing processes, such as deburring or painting after fabrication. That can increase production time and overhead costs.
Design Limitations // Sheet metal must have a uniform material thickness. Corners are created by bending metal. That’s why they must have minimum radii equal to the material thickness. Some bends may require relief notches to prevent unwanted deformation. Holes and tabs can’t be located too close to bends. Otherwise, bulges may occur. And there are some limitations on where you can locate welds to hold parts together.
Case Study //
Precision Sheet Metal Fabrication
VSi Parylene (VSi) provides advanced protective coating technologies for industrial and consumer electronics, aerospace and medical applications. Fathom played a key role in the launch of its POD Factory machine, which featured a sophisticated and challenging design. Fathom’s integrated, technology-agnostic approach and rapid response team enabled the customer to condense its product development cycle in half.
Post-Processing & Finishing
Sheet metal parts frequently require post-processing to remove burrs or sharp edges and to increase their aesthetic appeal. Fathom offers these post-processing services for sheet metal parts:
- Sanding and grinding
- Painting
- Powder coating
- Screen printing
- Assembly and kitting
Why Choose Fathom for Large Sheet Metal Fabrication?
Why Choose Fathom for Large Sheet Metal Fabrication?
Fathom has the expertise and technology to help you meet your sheet metal fabrication needs quickly and efficiently.
We can handle your project from concept and prototype to production. Our experts can advise you on changes that can help streamline the production of your parts. In some cases, we may be able to reduce their cost.
Our two locations that manufacture sheet metal parts, Denver and Ithaca, work with a wide range of part sizes. Both employ staff with decades of experience and expertise to help you achieve your design, prototyping and production requirements.
Additional Resources
Fathom Ithaca (Fathom’s Experts in Small Sheet Metal Prototyping)
Fathom Denver (Fathom’s Experts in Large Sheet Metal Prototyping)
Fathom Newark (Fathom’s Experts in Photo Chemical Etching)
