9 Ways to Reduce Sheet Metal Fabrication Costs

See how to cut costs without sacrificing quality for your next sheet metal project.

Sheet metal fabrication can be a very cost-effective means of production – assuming you do it right. Custom sheet metal fabrication services can cater to both startups and enterprises, offering rapid prototyping and high precision manufacturing using advanced technologies like laser and waterjet cutting.

If you’re sourcing sheet metal parts or thinking about it in the future, read on to see how to optimize costs from design to production.

Understanding the Sheet Metal Fabrication Process

The sheet metal fabrication process is a multi-step journey from concept to completion. It all starts with creating a 3D CAD model, which serves as the blueprint for your project. This model is then converted into a machine-readable format, setting the stage for the actual fabrication.

The first major step is cutting the sheet metal. Techniques like laser cutting are often employed for their precision and efficiency. Once the metal sheets are cut to the desired dimensions, they bend and form to achieve the required shapes. This is where the magic happens, transforming flat sheets into complex, functional parts.

After shaping, the parts are assembled, often using fasteners or welding, depending on the design requirements. The final touch involves surface treatments such as powder coating or anodizing, which not only enhance the appearance but also provide corrosion resistance.

Understanding each stage of the sheet metal fabrication process is crucial. It allows designers and engineers to create designs that are not only manufacturable but also optimized for cost and efficiency.

Streamline Design for Manufacturability (DFM)

Have you ever heard of the saying, “Less is more”? Well, it’s a golden rule in sheet metal design.

The more straightforward your design, the smoother the fabrication process goes, leveraging the full range of sheet metal fabrication capabilities. Before you get too carried away with intricate twists and curves, upload your part to our platform and let our engineering experts have a look. Their insights could reduce unnecessary costs, ensuring a seamless design-to-product transition.

Limit Custom Specifications

Standard sheet sizes, thicknesses, and grades are your friends. While making a unique piece with custom dimensions is tempting, remember that every custom spec can increase the price tag. Using standard sheet metal materials can significantly reduce costs and lead times.

Stick to the basics whenever possible.

Efficient Nesting and Layout

Maximizing the use of material through efficient nesting reduces waste.

By considering this during the design phase, you ensure that material utilization is optimized, leading to cost-effective quotations and production. Efficient sheet metal cutting techniques can further optimize material usage and reduce waste.

Utilize Standardized Hole Sizes and Corners

Utilizing standard tool sizes for features like holes and corners can expedite sheet metal fabrication processes and reduce costs. Designing with these standardized sizes ensures efficiency without unnecessary tool changes or setups.

Minimize Unnecessary Features

Every additional feature in sheet metal design introduces potential cost. Evaluate the necessity of each feature, ensuring that they are essential to the product’s function or aesthetics. Simplifying designs can make it easier to produce cost-effective metal sheet parts.

Opt for Common Materials and Finishes

Selecting widely available materials and finishes can be a significant cost-saving measure. While unique materials offer distinct advantages, they often come with a premium. Ensure the chosen materials align with the product’s requirements and budget considerations. Choosing the right sheet metal material can balance cost and performance effectively.

Aluminium is especially popular on the MakerVerse platform for many applications, as it offers a good balance of low cost and excellent properties.

Cost-Effective Manufacturing Techniques

Cost-effectiveness is key to sheet metal fabrication, especially for large production runs. One of the simplest ways to cut costs is by using standardized bend radii and minimizing the number of bends in your design. This reduces the complexity of the manufacturing process and speeds up production.

Another cost-saving strategy is to opt for readily available materials and fasteners. Custom or specialty items can significantly drive up costs and lead to longer lead times. By sticking to common materials, you ensure that your sheet metal parts are both affordable and quick to produce.

Additionally, consider using off-the-shelf components like card guides. These pre-made parts can simplify your design and reduce the need for custom fabrication, further lowering costs. By implementing these techniques, you can create sheet metal parts that are both cost-effective and meet all your design requirements.

Hardware and Assembly Considerations

Designing sheet metal parts isn’t just about the metal; it’s also about how everything comes together. When planning your design, it’s essential to consider the hardware and assembly requirements. This includes specifying the types of fasteners, screws, and other hardware needed to put the parts together.

Think about the assembly process itself. What tools and equipment will be required? Ensuring that the parts can be assembled efficiently and effectively saves time and money. Including a detailed hardware Bill of Materials (BOM) is also crucial. This document provides the manufacturer with all the necessary information to create accurate threads and features, ensuring nothing is overlooked.

By considering these factors during the design phase, you can create sheet metal parts that are easy to assemble and meet all the required specifications. This holistic approach to design and assembly can lead to significant cost savings and a smoother manufacturing process.

Factor in Tolerances

Precision is critical in sheet metal fabrication capabilities, but over-specifying tolerances can escalate costs. Familiarize yourself with the standard tolerances and design with these parameters to balance precision and cost. At MakerVerse, the standard minimum wall thickness is 0.5 mm, but it depends on the material and geometry.

Collaborate and Seek Feedback

We’re ready to help. Our engineering experts have decades of experience combined. They can help you uncover opportunities for further cost savings and design improvements. Our experts can guide you through the custom sheet metal fabrication process to find additional cost savings.

Consolidate Parts and Orders

Ordering multiple components simultaneously or merging several designs can streamline sheet metal fabrication processes and reduce setup and shipping costs. Consolidation can lead to economies of scale, ensuring cost-effectiveness throughout production.

Start Saving on Sheet Metal Fabrication

By being mindful of these strategies, designers can ensure that the transition from a design file to production is seamless and economically optimized.

When paired with an on-demand manufacturing platform like MakerVerse, sheet metal fabrication presents unique cost savings and efficiency opportunities. Selecting the correct sheet metal materials can further enhance cost savings and efficiency.