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

Sheet Metal Manufacturing

  • 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 Manufacturing

Trust Fathom for high quality parts made using the latest in 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.

Processes Used in Sheet Metal Manufacturing / /

Fiber Laser Cutting

Laser cutting machines make cuts within an enclosure using no mechanical components. The process uses laser diodes transmitted through optical fibers to cut the raw material. The enclosure decreases the risk to the machine operator while also producing less noise. Fiber laser cutting uses a high-power output and high-intensity level, making it a very efficient manufacturing process.

Waterjet Cutting

The waterjet cutting method uses a high-pressure pump to force water through a nozzle to make precise cuts. When a more abrasive cut is necessary, abrasive media is mixed with water. Both the water and abrasive can be recycled and reused, helping to increase energy efficiency while cutting down on costs.

Microcut™ Micro WaterJet Cutting

Microcut™ waterjet cutting uses manufacturing capabilities of waterjet cutting to create micro parts. Waterjet cutting’s high-level of accuracy is what allows Fathom to produce tiny and complex parts.

Wire EDM

During the wire EDM process, raw metal material is submerged in a dielectric bath where a charged thin metal wire uses electrical sparks to melt and cut the material. 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. 

Stamping

To stamp, a blank or coiled piece of sheet metal is placed on a press where a stamping tool presses into the material. The stamping tool or die contains the desired shape of the part. Stamping may include punching, blanking, bending, drawing, embossing and more.

Forming

During forming, sheet metal is loaded on a flatbed where a laser cutter draws pre-programmed parts onto the raw material. To add additional materials, a sheet metal punch may be used. The part is deburred and moved to a press brake for further shaping.

Prototype Etching

Prototype etching may include photochemical machining, chemical milling or acid etching. 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.

Production Etching

Production etching may include photochemical machining or chemical milling. Production etching produces parts with high precision and intricacies. The production etching method 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 to cut raw material. The laser cutting method 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

CNC punching equipment moves raw material along a 2-axis direction, placing it beneath a punching ram. The punching ram creates 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

Welding uses heat and pressure to fuse parts together. Welding may 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 a part of its complete sheet metal fabrication program. Fathom can ensure great quality and efficiency for projects with both low or high volume parts.

Sanding/Grinding

Fathom offers both sanding and grinding. Grinding adds a desired cosmetic surface and can also remove weld. Sanding deburrs and removes scratches from parts after they have been laser cut or punched.

Liquid Painting

Liquid painting is a finishing process perfect for projects where powder coating cannot be used. Liquid painting results in a professional finish, corrosion resistance, custom colors and more.

Powder Coating

During powder coating, the sheet metal part is coated evenly with powder and then cured. Once cured, the part has a professional finish that may be matte, smooth, textured and more. Fathom offers a variety of 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

Fathom performs assembly and kitting in-house. Services hardware installation, manual or automated processes and more. Fathom will ensure your finished part meets your exact specifications.

Sheet Metal Manufacturing Services Offered by Fathom / /

Fathom is ready to work with you on your sheet metal manufacturing project. Our services include waterjet cutting, laser cutting, photochemical machining, Microcut™ and more. Post-processing services like welding, bead blasting and deburring are also offered. Sheet metal manufacturing is just one of the 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

Metal Fabrication Quote Times / /

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

Sheet Metal Manufacturing Materials Available / /

Aluminum Alloys

Alloy Temper Ductility Strength Corrosion Resistance Heat Treatable Comments
6061 T6 Low Mid Good No Minimum bend radii of 3x raw material thickness.
6061 T0 High Low Good Yes Higher-cost heat treating due to warping and need for secondary straightening.
5052 H32 High Mid Good No Most commonly used aluminum alloy and temper.
5052 H34 Mid High Good No Small radii bends in line with grain may fracture.
3003 H14 High Low Good No Good for deep drawn parts.

Stainless Steel

Alloy Temper Ductility Strength Corrosion Resistance Heat Treatable Comments
301
302
304
*Range **High High Excellent No Small radii bends in line with grain may fracture in full hard temper. Full hard temper is cost effective for springs as there is no need for heat treating or plating.
316
316L
Annealed High High Excellent No Used heavily in the medical industry.
410 Annealed High Mid Mid Yes Excellent for springs. Stays stable in heat treating and has a bright finish.
17-4 PH Annealed Low Excellent Mid Yes Small radii bends in line with grain may fracture.
17-7 PH
Cond. A
Annealed Mid High Mid Yes Excellent for springs intended for repeated cycles. Remains stable during heat treating.
17-7 PH
Cond. C
Mill Hardened Low High Mid Yes Small radii bends in line with grain may fracture. Highest hardness and strength achievable in alloy 17-7 PH.

*Annealed, 1/2, 1/4, 3/4, and full hard possible
**Ductility decreases in harder tempers and mill hardened materials

Low Carbon and Spring Steel

Alloy Temper Ductility Strength Corrosion Resistance Heat Treatable Comments
1008
1010
Soft, 1/2, 1/4 Full Hard High Mid *Poor **Yes When rolled at or near room temperature, excellent ductility and strength is produced and is more uniform than hot rolled steel.
1008
1010
Annealed High Mid *Poor **Yes Rolled at a temperature greater than the recrystallization point, which produces surface scale. Good ductility, but weaker and less uniform than cold rolled steel.
HSLA Annealed Mid High *Poor **Yes Requires 25-30% more power to form than cold rolled steel or hot rolled steel.
1050
1074
1075
1095
Annealed Excellent ***High *Poor Yes 1095 has the highest carbon content of the materials listed. Higher carbon content yields higher strength with less ductility after heat treating.
1095 Blue Tempered Low High Mid No Good for flat springs or leaf springs with large radii.

*Poor without plating or surface treatment
** Limited to carburizing
*** High strength after heat treatment

Copper Alloys

Alloy Temper Ductility Strength Corrosion Resistance Heat Treatable Comments
C10 Cooper Wide Range High Mid Good No Highly conductive. High cost.
C172 Beryllium Copper Wide Range Excellent Excellent Fair Yes Excellent for electrical spring contacts. Highly conductive, excellent electroplating adhesion coefficient and remains very stable during heat treating. Moderate cost.
C260 Brass Wide Range *Ranges High Good No Small radii bends in line with grain may fracture in full hard and spring tempers.
C510 Phosphor Bronze Wide Range *Ranges High Fair No Small radii bends in line with grain may fracture in full hard and spring tempers.

*Ranges according to temper

Metal Fabrication Machines Used by Fathom / /

Mills, lathes, presses, press brakes, turret punches and additive machines are a few of the 530 machines, used by Fathom. Our equipment includes machines dedicated to sheet metal fabrication, including waterjet machines, lasers, 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.

In addition to sheet metal fabrication, Fathom also offers hybridized services that leverage sheet metal manufacturing. Do you need sheet metal fabrication as part of a complex project? Let Fathom take care of 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 Metal Fabrication Services / /

Fathom offers nationwide coverage to the entire United States, including 3 US-based locations offering sheet metal fabrication. Fathom’s manufacturing and prototyping services include injection molding, CNC machining, chemical etching, metal 3D printing and more. Fathom has provided over 200,000 quotes to leading US companies and are ready to give you a quote today.

Locations include:

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

Metal fabrication quotes FAQs / /

Q: Is Fathom ISO certified?

A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. 

Q: Is Fathom ITAR certified?

A: Yes, Fathom is ITAR certified.

Q: Is Fathom AS9100:2016 certified?

A: Yes, Fathom is AS9100:2016.

Q: Is Fathom NIST 800-171 certified?

A: Yes, Fathom’s certifications include NIST 800-171.

Q: How do you manufacture sheet metal?

A: A variety of manufacturing methods can be used to make sheet metal parts including wire EDM, stamping, forming and more.

Q: Is sheet metal a manufacturing process?

A: Sheet metal is a raw material that can be used for manufacturing.

Q: How are items manufactured using sheet metal?

A:  Sheet metal manufacturing can be used to make a wide variety of products including appliances, enclosures, chassis and more.

Q: What is sheet metal manufacturing?

A: Sheet metal manufacturing is the process of turning sheet metal into parts.

How to Get Metal Prototype Fabrication Quotes / /

Looking for a sheet metal fabrication quote? Ready to calculate costs for your next project? Use Fathom’s SmartQuote application to get 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