Automation in Custom Metal Fabrication - Increased Speed, Accuracy, and Perfection

 

Sheet metal fabricators turn flat metal sheets, such as aluminium and steel sheets, into custom metal structures or products by cutting, punching, folding, and assembling. There is increased pressure on sheet metal fabricators, often with tight turnaround times, and that’s why many custom metal fabricators are embracing automation. Automation results in higher productivity, as equipment can run for long periods of time with little input from operators, compared to manual processes. The staff are freed from manually intensive jobs, allowing them to focus on other tasks. Smart tools not only speed up the custom metal fabrication work, but also increase the safety of workers, as many jobs are done in an automated manner with minimal or no human intervention.

Common sheet metals used in fabrication projects include stainless steel, aluminium, zinc, and copper, and usually come in gauges between 0.006 to 0.25 inches in thickness. While thinner gauges are more malleable, thicker ones may be more suitable for strenuous applications. Sheet metal fabrication is widely used for industrial and consumer parts, and in specialist industries such as aerospace, automotive, energy and robotics.

Use of press brakes

Press brakes may be used by custom metal fabricators to create sharp bends and angles within the metals. Different types of press brakes are used in custom metal fabrication projects, and achieve different functions and bends. A variety of press brakes are available for use by sheet metal fabricators, such as mechanical, pneumatic, hydraulic and CNC. Mechanical press brakes are the oldest type of brake and are not suitable to supply air power for bending the metal sheets. A pneumatic press brake is used by sheet metal fabricators when less pressure is required and is most suitable for bending small metal parts or metals. A hydraulic press brake provides precise bending of metal sheets. CNC press brakes produce very accurate results and can bend sheet metals from just a few millimetres to meters long sections.

Press brakes can bend sheet metal into a V shape, U shape and angles of up to 120 degrees. De cambering can be used by custom metal fabricators to achieve just the opposite - removing the horizontal bend from strip-shaped pieces of sheet metal. Although press braking may seem to be a straightforward process, it can be difficult for the operators to remain consistent throughout the process and requires a certain level of expertise to achieve perfection.

Welding processes and techniques

Brisbane Metal Products (BMP) uses different welding techniques in its custom metal fabrication jobs to prevent warping and other abnormalities. They place emphasis on ensuring that the sheet metal fabrication is done exactly as per the exact specifications of a project.

Heat may be applied by sheet metal fabricators in a slow manner to remove abnormalities. Brisbane Metal Products has robotic welding systems with capabilities to make welding parameter changes in custom metal fabrication mid-process. The system provides for greater accuracy and repeatability, so sheet metal fabricators can take on longer runs and ensure consistent quality.

Defected metal may be straightened in custom metal fabrication using an oxy-acetylene torch. Brisbane Metal Products offers a complete range of custom metal fabrication services including full design services, CNC bending, laser and plasma cutting. Fibre optic laser cutters have an increased cutting speed and cut quality over conventional CO2 lasers. Laser cutting is typically used in industrial manufacturing, rail infrastructure and the medical sector. Laser cuts are designed to precisely etch and cut through a variety of materials, such as aluminium, stainless steel and mild steel, copper, and brass. It allows for the fabrication of more complex designs and enables custom metal fabricators to be more innovative.

Water jet and plasma cutters

Water jet cutting uses a high-pressure jet of water mixed with an abrasive substance to cut through the sheet metal. Water jet cutters are particularly useful for cutting sheet metal with a low melting point. This is because they do not generate heat, which could unduly deform a metal sheet with a low melting point. The plasma cutter creates an electrical channel of ionised gas, which forms a jet of hot plasma that can easily penetrate even thick gauges of sheet metal. Although less accurate than laser or water jet cutters, plasma cutters are fast and powerful, with low setup costs.

Automation for higher speed and accuracy

Brisbane Metal Products has invested in automation and higher speeds that ensure your custom metal fabrication job is completed on time and with perfection. Automation in custom metal fabrication ensures the utmost efficiency, minimal use of power and resources, and controlled movements. All these factors will add up to lower costs for your sheet metal fabrication jobs. Automation allows sheet metal fabricators and custom metal fabricators to meet high-quality project specs within shortened lead times.

Want to discuss your next custom metal fabrication project and benefit from the expertise of custom metal fabricators, sheet metal fabricators and state-of-art infrastructure of Brisbane Metal Products? Contact their friendly team today, and they will talk through your custom metal fabrication requirements with you for your next project. Though Brisbane-based, BMP has an extensive network of distributors all over the country, and delivers to overseas locations as well.