When designing parts for metal fabrication services, it’s a best practice to use standard sheet metal and metal tubing sizes. Straying from standard sizes can lead to exponentially higher costs and fabrication complexities.
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We’ll explain the standard sizes for sheet metal and metal tubing, why picking a non-standard size can make such a difference, and how Baillie Fabricating & Welding can guide you in the right direction for metal fabrication services.
In most materials, (i.e. Carbon Steel, Stainless, Steel, Aluminum) common sheet and plate sizes are 48” x 96”, 48” x 120” and 60” x 120”. You may also be able to get 72” x 144” sheets and plates. These are the most commonly available sizes of commercially available sheet and plate available at service centers.
Structural shapes include flat bars, L-angles, C-channels, I-beams, T-bars, hex and round bars. Commercially available sizes vary in length, width, and thickness depending on the specific material and grade.
In the metal tubing industry, common thickness and diameter standards can be found through online resources and supplier catalogs. However, lengths can vary by material and mill. Stainless steel is usually available at a maximum length of 20’ to 24’. Aluminum typically comes in 21’ and 25’ length. Steel tubing is generally available in 20’ lengths but can be ordered in specific lengths if there is a large volume of material ordered.
Steel Sheet is available in a variety of manufactured processes, such as hot rolled (HR), cold rolled (CR), hot rolled pickled and oiled (HRPO), as well as galvanized and galvaneeled finishes. Selecting one material over another is driven by the application and environment of the finished product.
Common stainless steel grades of sheet metal and plate are 304 and 316. The two finishes available for these sheets are a 2B mill finish or a #4 brushed finish. Many customers prefer the #4 brushed finish because it hides scratches much better than the 2B mill finish. The finishes run in the linear direction of sheet length. For example, in a 60” x 120” sheet, the grain will run in the 120” direction.
When using stainless steel tubing, be aware that the grain on square and rectangular tubes run lengthwise, while the grain on round tubes run around the circumference.
Aluminum sheets and tubes are not commercially available with grained finishes like a #4 finish, but can be grained at an additional cost.
Designing parts close to standard sheet metal and tubing sizes saves time and money. For example, if you need metal for a 41” x 51” part and use a 48” x 120” sheet, you’ll have significant material left over that you’ll have to pay for. The exact material makes a difference, too. The thickness of aluminum is measured differently than steel and stainless steel. Plus, the length and width of aluminum may vary from the other two metals.
Since metal is sold by weight, the price of the waste depends on the thickness of the material. If the sheet has a thin gauge, a small amount of scrap metal could cost $50. However, if the sheet has a thick gauge, the cost of wasted material could be more like $200. That’s per part, so the more parts you have, the more waste that results and the higher the cost of your metal fabrication services.
To minimize waste, try to design parts near 48" or 60" widths without going over. An odd width number like 49” means you’ll have to go up to the 60” width sheet and waste 11” of width.
When possible, orient the grain direction lengthwise to make the most out of your material. Running the grain widthwise will likely cause excess waste, but it can be done for aesthetic purposes if necessary. Grains are generally visible on stainless steel and aluminum. You rarely see the grain on steel because it typically gets a powder coating or some other finish.
Another occasion where aesthetics come into play is 96” x 96" projects. Since there’s not a sheet that big, seams and welds are required, and positioning is important. In this case, we may ask the customer, “Do you want the seam horizontally? Do you want it fully welded? Do you want a lap joint?” If it’s an industrial-based project, aesthetic-related details won’t matter as much.
When CAD Drafting your parts and assemblies, utilize standard sheet thicknesses commonly referred to as nominal thicknesses. These thicknesses can be easily obtained through catalogs available from service centers, or online resources. This will eliminate a lot of costs associated with redrawing parts to common material thicknesses.
Designing parts to be compatible with standard material sizes is the key to achieving cost-effective metal fabrication services.
If you have questions about your project, call (610) 701-, our team, or stop by our metal fabrication shop.
We can help you avoid wasted time and extra costs by designing your parts the right way from the start.
Are you unsure how to approach your sheet metal fabrication project? If you fail, your entire project could be blown. Mistakes made during the fabrication process are often impossible to rectify.
If you want to avoid the pitfalls most novices face, learn from the experts before you begin. In the sections below, you will find 6 tips from master fabricators. If you want to ensure your project goes off without a hitch, read on.
Your material costs and labor costs are the most significant costs in sheet metal fabrication. Plan to use stock sizes for your metal. If you are purchasing sheet metal in the USA sheet metal, you will purchase the thickness in a sheet metal gauge. Overseas you would purchase material in a metric thickness. It will save you up to 20% on metal costs when purchasing stock sizes.
Note that Sheet metal thickness gauges are based on the weight in pounds per square foot per inch of thickness. This means that to the novice, the interpolated thickness of the material will look funny. Also, note when considering a sheet metal fabrication project, the sheet metal thickness gauges for steel are based on a weight of 41.82 pounds per square foot per inch of thickness that the gauge thickness of aluminum and steel are different.
You also must choose your metals carefully. Assuming size and thickness are comparable, as far as the raw material cost, Carbon Steel is your least expensive type of sheet metal, followed by Aluminum, then Stainless Steel. More expensive choices include Brass & Copper.
Aluminum is the lowest in manufacturing cost, followed closely by Carbon Steel and Stainless Steel is the most expensive. This is because aluminum and steel basically up to 1/4″ can use a CNC sheet metal turret press and press break were on stainless steel anything above 1/16″ you must laser cut it the use a press brake which the laser cutting is a slower and more expensive process. As for the traditional sheet metal punch press, stainless steel must have a more robust expensive mold and higher ton capacity traditional sheet metal punch press.
If you have your heart set on a certain type of metal, ask yourself why. Is it a functional choice or a stylistic choice? If it’s stylistic, can you achieve the same results with powder coat, platings, anodizing or zinc-rich coating of industrial paint sheet metal fabrication needs?
If that’s the case, calculate the price difference. It might just save you a significant cost.
More than a few surfaces of your design will rarely be critical to your sheet metal fabrication product’s function. Unfortunately, most inexperienced engineers build their prototypes using unnecessary tight tolerance call-outs on every dimension, such as:
Unfortunately, the tighter call-outs you include in your design will cost the more expensive the finished product. Instead of falling into this trap, only include features and surfaces critical to your project’s function.
Just think of it this way: if you want to fabricate a piece of sheet metal, a flat, unadorned sheet would be the least expensive. Each bend, countersink, hem, and the hole will increase the price. The more work you make for your manufacturer:
The more you will have to PAY for your sheet metal fabrication.
Get back to the basics. Strip your design down to the bare minimum For your sheet metal manufacturing project.
Once again, using a standard option will save you big bucks in the long run. Every sheet metal fabricator offers slightly different options. The most common sheet metal gauge for the USA or standard millimeter thickness overseas for manufacturers runs up to one-quarter inch (6.35mm) thick. The thickness of the wall all depends on the project and the geometry of the part.
Thicker metals limit the angle of the bend you can achieve on a press brake. If the bend is too sharp, not only is it difficult to achieve on a press brake or even a traditional sheet metal punch press, it creates microscopic cracks in the metal. The cracks leave the metal brittle and easy to break.
You can also outright tear the metal. Many press brakes or traditional sheet metal mold punch press cannot be set up to make such bends. You run the risk of expensive setups and long production times.
If you want any complicated fabrication, just stay away from thick stock. Choose the thinner, more pliable metal.
Below you will find the most common specifications that novice fabricators mess up. Follow this quick and dirty chart, and it will save you both money and hassle.
Minimum Clearance Between a Hole and Bend or Hem: Place holes at a distance at least equal to the radius of the Bend or Hem plus the thickness plus 2.5X the material thickness. Bend radii should be equal to, or greater than, the radius of the curl plus 6 times the thickness of the metal.
Keep the outside radius of your Rolled Hems (Curls) to at least twice the thickness of the metal.
Countersinks: Separate each countersink from other countersinks by a distance equal to, or greater than, 8 times the metal’s thickness. They should also be separated from the corners by at least 4 times the thickness of the metal. They should be separated from a bend by at least 3 times the thickness of the metal or from an edge by 4 times the sheet metal thickness.
The depth of your countersinks should be no more than 3.5 times the thickness of your metal.
Tabs and Notches: In sheet metal Fabrication, keep your notches at least one-eighth of an inch away from each other. If you bend the notches, they need to be at least 3 times the thickness of the metal plus the bend radius. Tabs need to be 0.04 inches away from each other or more.
As you can see, sheet metal fabrication can make for a tricky project. The key is to map out your needs, step by step. Start with the final product design and work backward, determining each step you need to accomplish that goal and discuss you concept with a contract manufacturer.
If you have more questions or you would like to discuss your sheet metal fabrication with an expert, reach out to us today with any questions you might have or a DFM analysis on your concept.
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