{"id":2842,"date":"2026-07-18T07:08:29","date_gmt":"2026-07-17T23:08:59","guid":{"rendered":"https:\/\/bravofabs.com\/sheet-metal-fabrication-process-from-design-to-delivery\/"},"modified":"2026-07-25T22:32:00","modified_gmt":"2026-07-25T14:32:00","slug":"sheet-metal-fabrication-process-from-design-to-delivery","status":"publish","type":"post","link":"https:\/\/bravofabs.com\/sheet-metal-fabrication-process-from-design-to-delivery\/","title":{"rendered":"Sheet Metal Fabrication Process: From Design to Delivery"},"content":{"rendered":"

Sheet metal fabrication transforms flat metal sheets into finished parts through six precise stages. Understanding the workflow helps you communicate requirements clearly and get accurate quotes from manufacturers.<\/p>\n

\nProcess Flow: Sheet Metal Fabrication<\/strong><\/p>\n\n\n\n\n
\u2460 Design\/DFM<\/th>\n\u2461 Laser Cut<\/th>\n\u2462 CNC Bend<\/th>\n\u2463 Weld\/Assembly<\/th>\n\u2464 Surface Finish<\/th>\n\u2465 QC\/Inspection<\/th>\n<\/tr>\n
\u2193<\/td>\n\u2193<\/td>\n\u2193<\/td>\n\u2193<\/td>\n\u2193<\/td>\n\u2193<\/td>\n<\/tr>\n
\u00b10.05mm<\/td>\n\u00b10.1mm<\/td>\n\u00b10.1-0.2mm<\/td>\n\u00b10.2mm<\/td>\nPer spec<\/td>\nFull report<\/td>\n<\/tr>\n<\/table>\n<\/div>\n

Step 1: Design & DFM Review<\/h2>\n

Before any metal is cut, your CAD file undergoes a Design for Manufacturability (DFM)<\/strong> review. Our engineers check bend radii, hole-to-edge distances, and material thickness to catch potential issues before production starts. A thorough DFM report saves weeks of back-and-forth and prevents costly mistakes.<\/p>\n

Key DFM rules:<\/strong> Minimum bend radius \u2265 material thickness. Hole-to-edge distance \u2265 2\u00d7 material thickness (1.5\u00d7 minimum). Flange width \u2265 4\u00d7 material thickness. Distance between holes \u2265 2\u00d7 material thickness.<\/p>\n

Step 2: Blanking (Laser Cutting)<\/h2>\n

A high-power fiber laser cuts the flat pattern from sheet metal with \u00b10.1mm precision<\/strong>. For reference, a human hair is ~0.07mm \u2014 so we’re cutting to within 1.5 hairs of your target dimension.<\/p>\n

Laser cutting handles materials up to 8mm thick (carbon steel), 6mm (stainless), and 4mm (aluminum). For thicker sections or high volumes (>5,000 pcs), stamping provides faster throughput at lower per-part cost \u2014 though with higher upfront tooling investment.<\/p>\n

Common materials and max laser thickness:<\/strong><\/p>\n\n\n\n\n\n\n
Material<\/th>\nMax Laser Thickness<\/th>\nTypical Applications<\/th>\n<\/tr>\n
Aluminum 5052\/6061<\/td>\n4mm<\/td>\nEnclosures, panels, brackets<\/td>\n<\/tr>\n
Stainless Steel 304\/316<\/td>\n6mm<\/td>\nFood-grade, medical, marine<\/td>\n<\/tr>\n
Carbon Steel<\/td>\n8mm<\/td>\nStructural, heavy-duty<\/td>\n<\/tr>\n
Galvanized Steel<\/td>\n3mm<\/td>\nOutdoor, HVAC, electrical<\/td>\n<\/tr>\n<\/table>\n

Step 3: Bending (CNC Press Brake)<\/h2>\n

Flat blanks move to CNC press brakes where they’re formed into 3D shapes. Single bends achieve \u00b10.1mm tolerance; double bends \u00b10.2mm. The bend radius must be at least equal to the material thickness to avoid cracking at the bend line.<\/p>\n

Pro tip:<\/strong> Specify grain direction on your drawing \u2014 bending perpendicular to the grain reduces cracking risk and improves part strength. If your drawing doesn’t specify, we default to perpendicular \u2014 but confirming this in your RFQ avoids assumptions.<\/p>\n

Bend allowance quick reference (90\u00b0 bend, 1mm radius):<\/strong> 1mm sheet = 1.57mm allowance. 2mm = 3.14mm. 3mm = 4.71mm. Add this to your flat pattern length.<\/p>\n

Step 4: Welding & Assembly<\/h2>\n

Parts are joined using the appropriate process for the material and application:<\/p>\n