Practical Guide To Choose Sheet Metal Part Materials

Sheet metal parts are the foundation of every industry we see today. From automobiles to aerospace, from house facades to heavy machinery, they are everywhere. This diversity has led the machining industry to greater heights gradually. The tooling and machining industry in Europe has grown to 15.9 billion euros in 2024 from 12.4 billion euros in 2020. This shows the worldwide acceptance of the machining process. 

An efficient tooling process begins with the right sheet metal part selection. However, with so many options to choose from, it can overwhelm you to choose the right sheet metal fabrication part for your process. Join us as we make the part selection process easier for you. This article has everything you need to know to select the right sheet metal fabrication parts for any task.

What are the Different Types of Sheet Metal Fabrication?

Sheet metal fabrication is a process used to shape thin metal sheets. These sheets go through multiple processes like molding, welding, punching, bending, cutting and more based on the desired outcome. 

Let’s talk about some of the most popular sheet metal fabrication processes:

Cutting:

Cutting is one of the foundational metal fabrication processes. This helps manufacturers form sheets in specific sizes for various needs. In this step, both manual and automated processes are used, ranging from handheld plasma cutters to CNC machine cutting. 

Following different types of cutting are commonly used:

• Cutting with sheer (Manual and less precise process)

• Cutting without sheer (Semi or fully automatic, highly accurate)

The cutting type you choose entirely depends on the intended application. For example, sheet cutting is used in less critical uses and in small to medium industries. On the other hand, non-sheer cutting is utilized in high-end applications due to its precision and accuracy.

Forming

This is different from the cutting process. In cutting, we trim the sheets to get our desired size. However, in forming, we mechanically bend the sheet to achieve the desired shape and properties.

Forming is a multidimensional process. It commonly involves:

• Bending 

• Stamping

• Roll forming

• Stretching

• Spinning

Selecting the right forming process will mean reduced waste, greater design flexibility, better lead times, and quality that meets strict quality standards.

Punching

This process is used to cut holes into your custom sheet metal parts. A metal punch is used to perforate the sheets in the required locations. This process is effective for large-scale industries with varying tooling requirements.

Assembly

This is probably the most critical phase of the tooling process. It involves joining the individual parts to make the final assembly. One wrong step and the final product does not match the prototype.

This phase normally involves:

• Welding

• Riveting

• Brazing

• Industrial adhesives.

The type of assembling process used will depend on the product usage, your client’s budget and the overall finishing requirements.

Powder Coating (Optional)

Although this process doesn’t directly affect the mechanical properties of the final assembly, it is great to improve the overall finishing. In this process, an electrostatic powder is applied to a charged metal component (or to the complete assembly).

What are the most commonly used sheet metal materials?

Just like the diverse processes involved, the tooling process has an equally diverse range of metals used. The global sheet metal market is growing at a rapid rate, with revenues reaching US$484.6 billion by 2032. That’s an increase at a CAGR of 4.9%.

And, what are the metals contributing to this increase? Steel, Aluminum and others.

Here are some of the most commonly used materials in sheet metal parts:

Aluminium Alloys

Aluminum is widely used as a sheet metal part in various industries. Some of the common alloys of aluminum used in machining are:

• Aluminium 5052

• Aluminium 5754

• Aluminium 5083

• Aluminium 6060

With a tensile strength ranging from 173-540 Mega Pascal (MPa), these aluminum alloys serve various industries from automobile to aerospace.

Stainless Steel

Steel is known for its excellent weldability and exceptional tensile strength under stress. Some of the common alloys used for machining:

• Steel 1.0117

• Steel 1.0038

• Steel 1.0117

• Steel 1.7218

• Steel 1.0044

• Steel 1.0503

These steel alloys have a tensile strength of 350-630 Mega Pascal (MPa). With great corrosion resistance, good machinability, weldability and unmatched tensile strength, steel is one of the most used sheet metals worldwide.

Brass

Brass is an alloy of Copper and Zinc. Generally, brass has 55-95% Copper and 5-45% Zinc. When the zinc content is lower, Brass can easily be molded, brazed and worked with. On the other hand, a higher % of Copper alloys Brass to form an oxidative layer, which makes it corrosion-resistant. 

Although these are the most common sheet metals, there are other metals like Copper, mild steel, galvanized steel and titanium used for special applications.

This is how the cost comparison of various metals looks, with Copper being the most expensive option. Steel alloys are the workhorses of the tooling industry, and they provide great value for money.

Important mechanical factors in sheet metal material selection

There is one rule in any field: the more you know, the more you are stressed to make any decision. Now that you know about the various machining processes, types of sheet metal parts, it's now a difficult task to select the appropriate one for your process.

However, if you consider the following factors, you can select the right sheet metal material:

• Tensile strength (It’s important for structural components and load-bearing points)

• Yield Strength (critical in forming and bedding operations)

• Ductility (an important factor in automotive body panels and kitchen appliances)

• Hardness (it directly impacts durability and wear resistance)

• Formability (it affects the bending, punching and other forming operations)

• Impact resistance (higher impact resistance is a must in high-stress and vibrating environments)

• Corrosion Resistance (a must for long-term durability)

The right approach is to keep the end use in mind and then select the most appropriate material for the process. The above factors help indicate whether or not the chosen material can serve the purpose in your desired application.

What manufacturing and production processes can be performed with different metal sheets?

Custom sheet metal parts are used in nearly anything we see today. They are used from automotive sheet metal parts to electronics, furniture and everything in between. 

These are some of the industries/processes that benefit the most from metal sheets:

• Automotive Industry

• Aerospace Industry

• Construction & Architecture

• Industrial Machinery & Equipment

• Consumer Electronics

• Furniture & Interior Design

• Medical Equipment

• Electrical & Energy Sector

And, the list goes on…. These sheet metal parts are everywhere; we just need the eye to see them.

Final Words

Selecting the right sheet metal part can save you on additional rework costs, offer great durability and last longer in any machining project. If you keep the factors outlined above, you are sure to make the right choice that will align with your project requirements.

If you are looking for a top-notch sheet metal parts manufacturer, then look no further than BERGEK. With over 8 years of industry experience, and having worked on 120,000+ projects, BERGEK has developed an extensive range of custom sheet metal parts that are just right for your project requirements.

FAQ：

Q: What is the difference between sheet metal fabrication and stamping?

A: Fabrication is a broad term covering the entire process from cutting to assembly. Stamping is a specific high-efficiency forming process using dedicated dies, best suited for high-volume production.  

Q: Which grade of aluminum or stainless steel should I choose for my project?

A: For stainless steel, 304 is a general-purpose grade, 316 has superior corrosion resistance, and 430 is lower cost. For aluminum, 6061 is strong and weldable, 5052 is resistant to marine environments, and 3003 has good formability.  

Q: How thick can a CNC punch press handle?

A: As a rule of thumb, a typical CNC punch press can handle up to 3 mm stainless steel, 4 mm mild steel, and 5 mm aluminum.  

Q: What is the “4T rule” in sheet metal design?

A: The 4T rule is a key DFM guideline stating that holes or other features should be at least 4 times the material thickness (4T) away from a bend line to prevent deformation.  

Q: Why is ISO 9001 certification important for a sheet metal fabricator?

A: ISO 9001 certification indicates that a fabricator has a mature quality management system, ensuring consistent product quality, continuous improvement, and a focus on customer needs, which translates to higher reliability for the customer.  

Q: How is the cost of a sheet metal part calculated?

A: The cost is determined by multiple factors, including material cost, processing cost (machine time x rate), setup cost, labor cost, finishing cost, and overhead.  

Q: Is 3D printing cheaper than sheet metal fabrication?

A: It depends on the volume. For single prototypes or small batches, 3D printing is generally cheaper. For high-volume production, traditional sheet metal processes are far more cost-effective per part due to economies of scale.  

Q: How does anodizing work?

A: Anodizing is an electrochemical process mainly for aluminum. The part is immersed in an acid electrolyte bath, and an electric current is passed through it, causing a hard, durable, and corrosion-resistant aluminum oxide layer to form on the surface. This layer can also be dyed.  

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