The Earliest Instances of Metal Fabrication:
Sheet metal fabrication has been around for thousands of years, originating all the way back to 5000 BCE when civilisations began to form metal into sheets to make various objects (the metal was primarily gold). Fast forward a few thousand years and millennia of technological advancements and science has brought us to the sophisticated processes and machinery we use today.
The sheet metal industry is a cornerstone in the manufacturing sector. It is a fusion of technology, skill and innovation that encompasses a broad spectrum of industries. From automotive parts to retail fixtures, the versatility of sheet metal enables its widespread application, making it an indispensable force driving progress across diverse sectors of the global economy.
In this post we delve into some of the processes and machinery involved in a typical sheet metal processing unit and how they come together to bring you a finished product primed for the market.
CNC Machines: The Heart of Modern Fabrication
At the core of the sheet metal industry is the process of fabricating metal sheets into finished products. This involves several steps – cutting, bending, joining, and finishing. Each stage is vital to the manufacturing process and demands a high level of precision to ensure a quality end product. Manufacturing units like Ideal Design & Display are equipped with a range of tools and machinery to facilitate these processes, ensuring a consistent and high-quality product every time.
To gain a deeper understanding of how our products come together, let's look at some of these machines and processes:
1. Punching:
CNC punching machines are used to cut and shape metal sheets which forms the first part of the production process. Machines typically consist of a punch and die with modern machines having a turret or magazine of tools. This allows them to quickly change between different punch and die combinations to create various shapes and sizes in a single operation.
2. Laser Cutting:
Similar to punching machines, laser cutting machines are used to cut metal parts especially when complex shapes are required. Unlike punching, laser cutting is a non-contact process, reducing the risk of material warping when cutting. Since no tool changes are required, setup is simplified making it ideal for shorter runs. Laser cutting has been part of our production process for many years now, moving from the older CO2 systems to the newer fiber laser machines.
3. Bending:
Once parts have been cut to their desired specifications, they move to bending, where they are then transformed into 3 dimensional shapes. Press brakes achieve this through precise control of angles, dimensions, and a sequence of bends. The process involves placing a part on the die with a back gauge used to position it where the bend is required. The tool descends and presses the metal into the die, creating a bend as programmed. The back gauge automatically readjusts its position for the next bend in the sequence and this repeats till the final part is formed.
4. Welding:
Welding involves the application of heat, pressure, or both to fuse separate pieces of metal into one solid entity. This process is essential in creating durable, structurally sound products across various applications. MIG, TIG and Spot Welding are the most common in lighter gauge sheet metal applications. In addition to traditional welding, we at Ideal Design use robotic welding when doing medium to large production runs. Robotic welding allows us to achieve a precise, consistent, and high-quality weld at greater speeds than possible manually.
5. Finishing:
Welds often result in excess material at the joint (beads, slag, spatter) which can be unsightly. Therefore, once welding is complete, parts often require finishing. Grinding and sanding are used in the finishing process to smooth out any rough or uneven surfaces and create a more uniform product. This is especially important for some of our retail focused products.
6. Powder Coating:
To protect the metal components from corrosion and wear as well as enhance visual appearance, parts are then powder coated. Powder coating systems may differ from one facility to another so the following focuses on the system we have set up at Ideal Design. First, parts are hung on our automated conveyer system. They go through an automated wash booth where they are chemically sprayed under high pressure followed by a high-pressure water rinse to remove oils, dirt and contaminants. They are then dried in our drying ovens to remove any moisture before being passed through an automated spray booth. Powder here is applied using an electrostatic gun to ensure a uniform coat. Finally, the parts go into our drying oven where they undergo a "curing" process to form a smooth, hard, and durable coat.
7. Gasketing:
Gaskets are sealing components that fill the space between two or more mating surfaces, generally to prevent leakage from or into the joined objects while under compression. A gasketing machine is a specialized piece of equipment we use at Ideal Design for our IP rated enclosures. The gasket material, which in our process is in the form of a liquid, is fed into the machine and then deposited through a dispensing nozzle evenly along the metal surface. After the liquid gasket is applied, it is allowed to air dry to cure and solidify.
8. Assembly and Packing:
This is the final stage in our fabrication process where metal parts and various other components come together to form a finished product. Depending on the job, this could include acrylic, wood, MDF, electrical components such as lighting and screens, as well as print media. Units are either fully assembled, partially assembled or flat packed with assembly instructions depending on client requirements.
Quality Control:
Most if not all manufacturing units have a quality control process that differs industry to industry. Ideal Design prides itself on a stringent system where parts are checked at each stage of the manufacturing process with a final inspection done again during assembly and packing.
In addition to the operations mentioned above, here’s a look at some of our non-sheet metal focused processes:
1. Routing and Cutting:
Routing machines are versatile cutting tools used for a wide variety of materials. We primarily use these machines to accurately cut wood, acrylic, MDF and print media used for our retail displays. These machines offer unparallel speed and precision when it comes to cutting and can handle complex shapes much like our CNC laser cutting systems.
2. Printing:
We use a number of printing techniques for our customers both in the retail and industrial sectors. Large format printing, UV printing and screen printing are some of the processes we utilise in house. For our retail projects we use several large format printers to create eye-catching branding for our customers. Being able to print on multiple materials with a very high-quality output makes them essential for a myriad of visual merchandising solutions. Our UV flat bed printers are also capable of printing high quality branding, resistant to fading and weathering in harsher outdoor environments. Not to mention, they can also print directly to materials such as wood, metal and acrylic allowing for greater freedom when designing unique brand experiences.
Looking to the Future:
In the dynamic landscape of the sheet metal industry, Ideal Design and Display has stood as a prime example of excellence and innovation. With over 25 years of experience, our company has adapted and grown to meet the demands of an ever-changing manufacturing environment. Through the seamless integration of advanced technologies, skilled craftsmanship and rigorous testing, we are well positioned to meet the evolving needs of a diverse range of industries.
Whether you needs parts manufactured, ideas conceptualised or solutions engineered, Ideal Design is your one-stop-shop for all your fabrication needs. Get in touch with our team today!