Views: 0 Author: Site Editor Publish Time: 2024-12-07 Origin: Site
Sheet metal fabrication is often mistakenly viewed as a commodity process—simple cutting, bending, and welding of thin gauge material. In reality, it is a precision manufacturing system that integrates material science, digital engineering, and adaptive automation to produce functional components at scale. Unlike stamping (high capital, rigid tooling) or CNC machining (high material waste, slow), sheet metal fabrication occupies a unique sweet spot: geometric flexibility, cost-effective tooling, and rapid time-to-market for low-to-mid volumes (10 to 100,000 parts).
The global market reflects this strategic value. Sheet metal fabrication services are projected to exceed $450 billion by 2028, driven by reshoring, EV manufacturing, and modular infrastructure. But success hinges not on simply owning a laser cutter or press brake—it depends on engineering-led decision making across the entire value chain: design, material selection, process sequencing, and supply chain integration.
This guide provides a strategic framework for leveraging sheet metal fabrication as a competitive advantage rather than a passive manufacturing step.
Choosing sheet metal over casting, extrusion, or machining requires evaluating five variables:
| Factor | Sheet Metal Fabrication | Die Casting | CNC Machining | Metal Injection Molding (MIM) |
|---|---|---|---|---|
| Volume | 10 – 100,000 parts | 10,000 – 1M+ parts | 1 – 5,000 parts | 5,000 – 100,000 parts |
| Tooling Cost | $0 – $5,000 (soft) | $50,000 – $500,000 | $0 (programming) | $20,000 – $100,000 |
| Design Iteration | Same day (CAD change) | 6-12 weeks (die mod) | Same day (CAM edit) | 4-8 weeks (tooling) |
| Part Complexity | 2D → 3D bends; moderate undercuts | Complex geometry, thin walls | All geometries (5-axis) | Small, intricate (±0.002") |
| Material Yield | 80-95% (nesting) | 95% (net shape) | 10-30% (subtractive) | >95% (net shape) |
| Lead Time | 3-7 days (prototype) | 12-16 weeks | 1-3 weeks (first article) | 8-12 weeks |
Key Insight: Sheet metal fabrication dominates when design volatility is high, volumes are moderate, and material thickness is 0.024" to 0.25" (0.6-6.35 mm). For thicknesses below 0.024", photoetching or stamping is more precise; above 0.25", machining or casting becomes cost-competitive.
80% of manufacturing cost is locked in during design. In sheet metal, DFM is not a suggestion—it is a financial imperative. Common design errors and their cost impact:
| Design Flaw | Impact | Cost Multiplier | Corrective Action |
|---|---|---|---|
| Bend radius < 1T | Cracking, tool wear | 3-5x (rework, scrap) | Use R ≥ 1.5T for steel, 2T for aluminum |
| Hole too close to bend (≤4T) | Hole deformation | 2-3x (redrill) | Maintain 4T minimum distance |
| Missing bend relief | Tearing at corners | 5x (scrap) | Add 0.5T × bend radius relief notch |
| Unnecessary tight bend tolerances | Premium tooling, slow setup | 2-4x (hourly rate) | Specify ±1° standard; use ±0.5° only if critical |
| Complex nesting | Low material utilization | 1.5-2x (material waste) | Design with common bend lines; use DXF nesting software |
Bend Allowance & K-Factor: The neutral axis shift during bending is calculated via K-factor (typically 0.3-0.5). For a 90° bend in 0.125" steel with K=0.4:
Bend allowance = (π/180) × (R + K×T) × Angle
BA = 1.57 × (0.125 + 0.4×0.125) = 1.57 × 0.175 = 0.275"
Accurate calculation ensures flat patterns yield correct final dimensions, eliminating trial-and-error.
Grain Direction: Bending perpendicular to the rolling direction reduces cracking risk by 70%. DFM should specify grain orientation on drawings.
Hole Patterns: Use standard punch tooling (round, obround, square) to avoid custom tooling costs ($200-$500). Slots with radiused ends fit standard obround punches.
Nesting Optimization: Advanced nesting software (SigmaNEST, Radan) achieves 85-95% material utilization vs. 70% manual nesting, saving $5,000-$15,000 per month on typical job shop material spend.
Material choice dictates everything: cost, formability, corrosion resistance, and finish. The wrong alloy can triple processing costs.
5052-H32: Ultimate tensile strength 33 ksi, elongation 12-18%. Excellent formability. First choice for deep bends, complex forming. Cost: $2.50-$3.50/lb.
6061-T6: UTS 45 ksi, but elongation only 8-10%. Prone to cracking on tight bends (R<2T). Use only when strength is critical. Cost: $2.80-$4.00/lb.
3003-H14: UTS 22 ksi, elongation 16%. Ideal for spinning, shallow draws. Cost: $2.20-$3.00/lb.
Key Decision: If a part requires a 0.5T bend radius, 5052-H32 is mandatory. Using 6061-T6 would require annealing (softening) before bending, adding $0.50/part in processing.
ASTM A36: Carbon steel, yield 36 ksi. Excellent weldability, poor corrosion resistance. Requires coating (paint, zinc). Cost: $0.60-$0.90/lb.
ASTM A572 Grade 50: Yield 50 ksi. Higher strength for structural brackets. Slightly lower formability. Cost: $0.70-$1.00/lb.
HSLA (High-Strength Low-Alloy): Yield 50-80 ksi. Allows thinner gauges, weight savings. Used in automotive body-in-white. Cost: $0.80-$1.20/lb.
Galvanized (G90): A36 with 0.90 oz/ft² zinc coating. Direct cost $1.20-$1.50/lb, but eliminates post-fabrication painting cost.
Critical Factor: Galvannealed steel (zinc-iron alloy) offers superior weldability (less zinc vapor) and paint adhesion vs. galvanized, making it the standard for automotive body panels.
304: 18% Cr, 8% Ni. Good general corrosion resistance. Difficult to form (work hardens rapidly). Cost: $3.50-$4.50/lb.
316L: 16% Cr, 10% Ni, 2% Mo. Superior chloride resistance (marine, chemical). First choice for medical/pharma. Cost: $4.50-$5.50/lb.
409: 11% Cr (ferritic). Lower cost ($1.80-$2.20/lb) for automotive exhaust (corrosion resistance up to 1200°F).
Process Note: Stainless requires passivation (ASTM A967) after fabrication to restore the passive Cr₂O₃ layer damaged by welding and cutting. Skipping this step can cause tea staining and pitting within weeks.
| Process | Thickness Range | Cut Quality (Ra) | Tolerance | Speed (0.125" steel) | Cost/hour | Best For |
|---|---|---|---|---|---|---|
| Fiber Laser | 0.020" - 1.00" | 80-120 µin | ±0.003" | 300 in/min | $80-$120 | Precision parts, intricate contours |
| CO2 Laser | 0.020" - 0.75" | 120-200 µin | ±0.005" | 200 in/min | $60-$90 | Non-ferrous (Al, Cu) |
| Plasma | 0.125" - 2.00" | 200-500 µin | ±0.015" | 150 in/min | $40-$70 | Thick steel, rough cuts |
| Waterjet | 0.020" - 6.00" | 150-250 µin | ±0.005" | 50 in/min | $100-$150 | Heat-sensitive materials, thick stock |
| CNC Punching | 0.020" - 0.375" | 200-400 µin | ±0.005" | 500 hits/min (holes) | $50-$80 | High-volume holes, louvers, forms |
Strategic Selection Example: A bracket with 50 holes and 2 large cutouts. Punch the holes (0.5 sec/hole) and laser the perimeter (speed + quality). Combined turret-laser machines (e.g., Amada LC series) do both in one setup, reducing handling time 40%.
Air Bending (most common): V-die with 30° included angle. Bend angle controlled by punch depth. Springback compensation required: 2-5° for steel, 4-8° for stainless, 8-12° for aluminum. Modern CNC brakes use crowning systems (hydraulic or mechanical) to compensate for ram deflection, achieving ±0.5° across 10-foot parts.
Bottom Bending: Punch forces metal into V-die, coining the bend. Reduces springback but requires 3-5x tonnage. Used for high-precision (±0.2°) or for bending high-strength steel.
Tooling Cost: Standard V-dies: $200-$500. Gooseneck punches for deep boxes: $800-$1,500. Custom forming tools for complex profiles: $2,000-$10,000 (amortize over 500+ parts).
Bend Sequence Optimization: Software (AutoForm, Dynaform) simulates bend order to prevent collision and minimize part flipping, reducing cycle time 25%.
MIG (GMAW): 90% of production welding. Pulsed MIG (e.g., Miller Dynasty) reduces heat input 30%, minimizing distortion on thin gauges. Robotic MIG achieves 99% repeatability, essential for automotive seat frames.
TIG (GTAW): For critical welds (pressure vessels, medical). AC TIG for aluminum (cleaning action), DC TIG for steel/stainless. Automated cold-wire TIG increases deposition rate 2x while maintaining quality.
Laser Welding: Fiber lasers (1-6 kW) weld at 100 in/min with 0.5 mm spot size. Key advantage: Minimal heat-affected zone (HAZ) <0.5 mm, enabling welding near heat-sensitive components. Cost: $150-$250/hour; justifiable for high-value parts (battery enclosures).
Distortion Control: The #1 quality issue. Strategies:
Weld sequence: Alternate sides, backstep welding
Clamping: Fixture with copper backup bars to sink heat
Post-weld: Stress relief at 1100°F for 1 hour (for critical parts)
World-class fabricators don't inspect quality in—they control the process. Key metrics:
First-pass yield (FPY): Should exceed 95%. Each 1% drop in FPY adds $50K-$100K annual cost for a mid-size shop.
Cpk (Process Capability): For critical dimensions (hole position, bend angle), target Cpk ≥1.67 (99.999% within spec).
PPM (Defect Rate): Automotive standard is <50 PPM (50 defects per million parts). Typical job shop runs 500-2000 PPM.
In-Process Monitoring:
Laser cut: Monitor assist gas pressure (N₂ for stainless, O₂ for steel), focal position (±0.5 mm), and kerf width (0.008-0.020").
Bending: Use angle-measuring lasers (e.g., Lazer Safe) to verify bend angle in real-time, adjusting for material variation.
Welding: Monitor voltage, amperage, and wire feed speed; WPS (Welding Procedure Specification) compliance is mandatory for AS9100.
CMM (Coordinate Measuring Machine): Measures hole positions to ±0.0005". Pro tip: Use fixture-based CMM to inspect 10-20 features simultaneously.
Borescope: Inspects internal weld penetration in tubular structures.
Coating thickness: Eddy current for non-magnetic (aluminum), magnetic for steel per ISO 2178.
Adhesion testing: Cross-hatch tape test (ASTM D3359) for paint; cupping test (ISO 1520) for formability validation.
| Cost Element | $/Part | % of Total |
|---|---|---|
| Material | $2.00 | 35% |
| Laser Cutting | $1.20 | 21% |
| Bending (2 ops) | $0.80 | 14% |
| Welding (2 welds) | $1.00 | 18% |
| Powder Coating | $0.60 | 10% |
| Packaging | $0.10 | 2% |
| Total | $5.70 | 100% |
Key Cost Levers:
Material utilization: Improving nesting from 75% to 90% saves $0.40/part ($400 on 1000 pcs).
Setup time: Modern CNC brakes with automatic tool change reduce setup from 45 min to 10 min, saving $0.30/part at $75/hr shop rate.
Batch size: Setup cost amortization: 10 parts = $50/part; 100 parts = $5/part; 1000 parts = $0.50/part.
Total Cost of Ownership (TCO):
Tooling amortization: $5K soft tooling (punch/die) for 1000 pcs adds $5/part. If volumes are <500, laser cutting is cheaper despite slower per-part speed.
Warranty risk: A $0.10/part savings on cheaper zinc plating vs. powder coating could cost $50/part in field corrosion failures. Specifying 240+ hour salt spray is insurance.
The difference between a vendor and a partner is engineering engagement and process control maturity. Evaluate on:
Equipment ages: Lasers <5 years old have 30% lower operating costs and better cut quality. Press brakes >10 years lack modern crowning and angle control.
Capacity alignment: A shop with two 4kW lasers and one 6-axis brake can handle $2M-$5M annual spend. Overloading causes lead time slip.
Vertical integration: In-house powder coating, assembly, and packaging reduce your vendor management overhead by 60%.
Certifications: ISO 9001 is baseline. IATF 16949 (automotive) or AS9100 (aerospace) indicates robust process control, not just paperwork.
Data-driven quality: Ask for Cpk data from recent runs. A Cpk <1.33 signals unstable process.
Traceability: Can they link a part serial number to material heat lot, operator, and machine? Critical for regulated industries.
DFM feedback: Top-tier shops return DFM comments with quotes, suggesting material thickness reductions, bend radius standardization, or weld accessibility improvements.
Prototyping speed: 3D CAD → laser cut prototype in 48 hours indicates agile workflow.
Design software: Do they use SolidWorks, Inventor, and can they open native files? Translating to STEP risks tolerance loss.
Quote automation: Online portals for simple parts indicate process maturity and transparency.
MES integration: Real-time job tracking, digital work instructions, and automated inspection data capture reduce your risk of undocumented deviations.
Supply chain visibility: Kanban or VMI (Vendor Managed Inventory) programs cut your carrying costs 20-30%.
No formal quality manual → inconsistent output
Unable to provide material certs (MTRs) → counterfeit material risk
Excessive subcontracting (>30% of processes) → loss of control
No capacity planning system → lead time slip risk
IoT-enabled equipment: Lasers and brakes transmit vibration, temperature, and cycle data to predict maintenance, reducing unplanned downtime 40%.
AI nesting: Machine learning algorithms optimize part orientation and common-line cutting, squeezing an extra 5% material utilization—worth $50K-$100K annually.
Digital twin: Simulate bend sequences and springback before first hit, cutting first-article time from 4 hours to 30 minutes.
Powder coating: 98% material reclaim, zero VOC vs. liquid paint's 40% overspray and hazardous waste.
Closed-loop waterjet: Recycles 95% of water and abrasive, cutting disposal costs 80%.
Material recycling: Scrap skeletons are directly fed into shredders and returned to mills, achieving 95% material circularity.
3D printed features: Additive manufacturing creates complex mounting bosses or heat sinks, then welded to formed sheet metal housing. Reduces machining cost 60%.
Laser-assisted forming: Localized laser heating reduces bend force 30%, enabling forming of ultra-high-strength steel (UHSS) without cracking.
Sheet metal fabrication is not a back-end manufacturing task—it is a front-end competitive strategy. To maximize ROI:
Engage fabricators at the concept phase. Early DFM review saves 30-50% in lifecycle cost by avoiding material waste, excessive tooling, and quality failures.
Specify performance, not just dimensions. Require CO₂eq per part, salt spray hours, Cpk on critical features, and first-pass yield data.
Audit for industry-relevant certifications. ISO 9001 is insufficient for automotive (IATF 16949) or aerospace (AS9100).
Invest in digital twin prototyping. Simulate forming and welding before cutting metal; the software cost ($10K-$20K) pays back on the first complex project.
Think in total cost of ownership. A $0.20/part cheaper quote that results in 2% field failure rate will cost 10x more in warranty claims.
The future of sheet metal fabrication belongs to engineers who treat it as a system, not a shop transaction. Those who master the interplay of material, process, and quality control will deliver products that are lighter, stronger, cheaper, and faster to market—turning fabrication from a cost center into a market advantage.
Sheet metal fabrication is a multi-stage manufacturing system that transforms flat metal sheets (0.006"-0.25" thick) into functional 3D components through integrated material processing. It's not a single operation but a value stream with interdependent stages:
Engineering & DFM: CAD modeling with bend allowance calculations, K-factor determination (0.3-0.5), and nesting optimization (85-95% material utilization)
Cutting: Laser, plasma, waterjet, or punching to create 2D blanks with ±0.003" tolerance
Forming: CNC press braking with springback compensation (2-5° for steel) and crowning systems for ±0.5° angle control
Joining: MIG/TIG/spot welding with fixture control to minimize distortion; quality confirmed via Cpk ≥1.67
Finishing: Powder coating (98% material reclaim), plating, or passivation per ASTM A967
Assembly & Kitting: Integration of PEM fasteners, gaskets, and subcomponents; can include electromechanical assembly
Critical Distinction: Unlike stamping (hard tooling, 50K+ volumes) or machining (subtractive waste), sheet metal fabrication excels at low-to-mid volumes with high design volatility, where engineering agility outweighs tooling investment.
The implementation sequence breaks into value-added operations:
Phase 1: Preparation
Nesting: Software arranges parts on sheet to maximize utilization; common-line cutting reduces scrap 15-30%
Material prep: Deburring edges post-cut to prevent crack initiation during bending
Phase 2: Primary Forming
Cutting: Laser (precision), punching (high-speed holes), or shear (straight edges)
Bending: Sequence optimization to prevent interference; typically 2-8 bends per part
Stamping/Forming: Optional for features like louvers, embossments, or deep draws
Phase 3: Joining & Assembly
Welding: Robot MIG for repeatability; TIG for aesthetic/critical joints
Fastening: PEM insertion, riveting, or clinching
Hardware installation: Captive nuts, standoffs, hinges
Phase 4: Finishing & QA
Surface prep: Alkaline cleaning, blasting, or conversion coating
Coating: Powder coat (electrostatic), e-coat (immersion), or plating (electrolytic)
Inspection: CMM for critical dims; cross-hatch for adhesion; salt spray for corrosion
Phase 5: Logistics
Kitting: Subassemblies with hardware bagged
Packaging: Custom dunnage to prevent shipping damage
Cycle Time: A simple bracket (cut, bend, powder coat) flows in 3-5 days; complex welded assembly with hardware may require 7-10 days.
A foundational DFM constraint: The minimum distance between any feature (hole, edge, notch) and a bend line must be ≥ 4 times the material thickness (T).
Why it matters: Bending creates tensile stress on the outer surface and compressive stress on the inner surface. If a hole is within 4T, the stress concentration causes:
Cracking: Material tears along the hole edge
Distortion: Hole becomes oval, losing precision
Tool damage: Punch stress riser accelerates wear
Example: In 0.125" (3.175 mm) steel, holes must be ≥0.5" (12.7 mm) from bend lines. Violating this rule can increase scrap rate from 2% to 15% and necessitate secondary operations (reaming, weld repair).
Exceptions: Relief notches (0.5T × R) can be strategically placed to allow closer features, but this adds cost and stress risers.
The core operations are cutting, bending, punching, joining, and finishing—but this oversimplifies the strategic process. A more useful classification:
1. Shearing Operations (Cut material without chip formation)
Blanking: Cut part outline; the piece is the "blank"
Piercing/Punching: Create holes; the slug is waste
Notching: Remove material from edges (for bend relief)
Shearing: Straight-line cuts (use guillotine shear)
2. Forming Operations (Plastic deformation without cutting)
Bending: V-die, air, or bottom bending on press brake
Stamping: Die-based forming (emboss, coin, draw)
Rolling: Curved shapes via three-roll benders
Hemming: Folding edge back onto itself for safety/stiffness
3. Joining Operations (Assemble multiple pieces)
Welding: MIG, TIG, spot, laser
Fastening: Rivets, PEMs, screws
Adhesive bonding: Structural epoxy (requires surface activation)
4. Finishing Operations (Surface engineering)
Cleaning: Deburring, degreasing
Coating: Powder coat, e-coat, plating
Treatment: Passivation, anodizing
5. Value-Added Operations (Integration)
Hardware insertion: Automatic PEM presses
Assembly: Kitting with purchased components
Testing: Leak test, load test, electrical continuity
A strategic classification based on material flow:
1. Subtractive (Cutting)
Removes material to create shape
Methods: Laser, plasma, waterjet, shear, punching
Best for: Perimeter profiles, holes, cutouts
Limitation: Material waste; limited 3D shaping
2. Deformation (Forming)
Changes shape without removing material
Methods: Bending, stamping, rolling, stretching
Best for: Angles, curves, structural rigidity
Limitation: Springback, cracking risk on tight radii
3. Additive/Assembly (Joining)
Combines pieces or adds features
Methods: Welding, riveting, PEM insertion, adhesive bonding
Best for: Complex assemblies, hardware mounting
Limitation: Distortion, joint strength variability
Hybrid Approach: Modern fabrication sequences these in CAD/CAM. A typical part: Cut blank → Punch holes → Bend 3D shape → Weld brackets → Insert PEMs → Powder coat.
Both are shearing operations but serve opposite purposes:
Blanking: The part itself is the desired piece. A punch press cuts the outline from sheet; the blank falls out as the product. The perimeter is the critical dimension. Used for:
Washers: Round blanks
Brackets: Complex outlines
Deep-drawn parts: Pre-forms for cups/shells
Die clearance: For 0.125" steel, use 10% clearance (0.0125") between punch and die. Too tight causes edge burring; too loose creates rollover and poor edge quality.
Piercing (Punching): The hole is the desired feature; the slug is scrap. Punch creates internal features (holes, slots). Critical dimensions are hole diameter and location.
Tooling cost: Blanking dies cost $2,000-$10,000; piercing punches are $50-$200 each. For volumes <1,000, laser cutting is cheaper than hard tooling.
Industry standard: The threshold is 0.25" (6.35 mm).
| Classification | Thickness Range | Forming Method | Equipment |
|---|---|---|---|
| Foil | <0.005" (0.13 mm) | Hand forming, stamping | Foil rolling mills |
| Sheet | 0.005" - 0.25" (0.13-6.35 mm) | Press brake, roll forming, stamping | 50-500 ton brakes |
| Plate | >0.25" (6.35 mm) | Hot forming, rolling, machining | Plate rolls, 1000+ ton presses |
Process Implications:
Sheet metal: Cold forming at room temperature; minimal springback; standard press brakes
Plate: Requires hot forming (900-1200°F) to avoid cracking; 10x higher tonnage; post-form stress relief
Cost Impact: Plate processing is 3-5x more expensive per pound due to equipment requirements and slower speeds.
Essential heuristics for rapid DFM validation:
Bend Radius: Minimum R = 1x thickness for steel, 1.5x for stainless, 2x for aluminum (to avoid cracking)
Hole Size: Minimum hole diameter = 1x material thickness (for punching). Smaller requires drilling or laser.
Bend Relief: Relief notch width = 0.5x thickness × bend radius
Bridge Width: Minimum material between holes = 2x hole diameter (to prevent distortion)
Curling/Flanging: Edge curl diameter ≥ 4x material thickness
Forming Limit: Maximum reduction in deep drawing = 40% for steel, 50% for aluminum
Grain Direction: Bend line perpendicular to grain for +70% formability
Tolerance: General tolerance ISO 2768-mk (±0.5 mm) unless specified otherwise
These rules prevent 90% of DFM failures and should be embedded in CAD design checkers.
A strategic competency framework for engineers:
Material Science:
Alloy properties (UTS, elongation, work hardening exponent n-value)
Coating types (zinc, galvalume, paint systems)
Corrosion mechanisms (galvanic, pitting, crevice)
Process Physics:
Shear vs. fracture mechanics in cutting
Springback theory (elastic recovery, K-factor)
Heat-affected zones in welding (HAZ width <3mm for TIG)
Surface energy for coating adhesion (>38 mN/m)
Quality Systems:
Tolerance stack-up analysis for assemblies
Weld symbol interpretation (AWS A2.4)
Cpk and SPC for process control
First-article inspection (AS9102 for aerospace)
Economic Modeling:
Setup cost amortization over batch size
Material utilization vs. nesting time optimization
TCO including warranty risk from coating failure
Safety & Standards:
OSHA 1910.212 machine guarding
ANSI B11.3 press brake safety
ISO 13849 safety PL (Performance Level) for automation
Mastering these fundamentals reduces design iterations by 60% and avoids costly late-stage engineering changes.
Industry-standard taxonomy per ISO 9013 and AWS D9.1:
A. By Material Flow:
Shearing Operations (cutting)
Blanking, piercing, notching, trimming, shaving
Forming Operations (plastic deformation)
Bending, drawing, stretching, roll forming, flanging
Joining Operations (assembly)
Welding (arc, resistance, laser), mechanical fastening, adhesive bonding
Finishing Operations (surface engineering)
Cleaning, coating, conversion treatment
B. By Automation Level:
Manual: Hand shear, manual brake, stick welding
Semi-Automatic: CNC punch, press brake with backgauge, MIG with wire feed
Fully Automatic: Robotic welding cells, automated panel benders, lights-out laser cutting
C. By Production Volume:
Job Shop: 1-100 pieces, soft tooling, high setup time
Batch: 100-10,000 pieces, dedicated fixtures, moderate automation
Mass Production: 10,000+ pieces, hard tooling, synchronous transfer lines
A production-flow perspective (vs. technical steps):
Stage 1: Engineering Release
CAD finalized, GD&T applied, material specified, nesting completed
Output: DXF/Nested files, BOM, work instructions
Stage 2: Material Prep
Sheet received, validated for thickness, coating, MTR
Cut into blanks or loaded onto laser bed
Stage 3: Primary Processing
Cutting, punching, notching (2D to 2D with features)
Goal: Create flat pattern that will fold correctly
Stage 4: Secondary Forming
Bending, rolling, stamping (2D to 3D)
Critical: Sequence determines final geometry success
Stage 5: Joining & Assembly
Welding, PEM insertion, riveting (multiple 3D parts → assembly)
Challenge: Controlling distortion and maintaining tolerances
Stage 6: Finishing
Surface prep, coating, marking (functional/aesthetic enhancement)
Key: Pretreatment (phosphate, conversion coating) determines coating life
Stage 7: Final QA & Logistics
Dimensional inspection, functional test, kitting, packaging
Output: Certified parts ready for customer integration
Lead Time Drivers: Stages 1-3 (cutting) = 1-2 days; Stages 4-5 (forming/joining) = 3-5 days; Stage 6 (finishing) = 2-3 days; Stage 7 = 1 day.
