What is metal fabrication?

Metal fabrication is the process by which raw material is turned into a usable part of an assembly process.  There are seven common ways by which this can be accomplished and more are being added as technology is improved upon.

  • One of the most popular ways to work with raw metal is to cut it.  This is typically done with a saw.  However, torches, water jets, and lasers can also be used and can result in a more precise cut.
  • Often when it comes to sheet metal design, a piece may need to be bent for proper placement.  A press brake is the most common method.  The brake pinches the metal in order to form a crease.  However, this operation can only be performed in very specific cases due to the movement of the part and the possible shape of the dies being used to do so.  Additionally, complex shapes can slow down the entire operation and it may be more beneficial to use two different processes, instead.  Another option is to use two different pieces fastened together.
  • Machining is the process of removing metal from a piece of material usually on a lathe.  A lathe is a machine that that rotates the piece being worked on on its axis in order to perform various operations.  While the material rotates, it is placed against a cutting tool or some other cutting machine where a rotating tool is moved in a variety of ways against a stationary piece.
  • Punching is the act of a placing a hole in the material.  The punch and die must be the same shape and size of the desired hole. There are two different reasons for punching to be used.  The first is when the main piece of material is kept, as in when holes are added for fasteners. In other cases, the piece that is removed is the desired product.  If that is the case, then the process is called blanking.
  • If you have ever used a paper cutter that looks like a guillotine, then you know how to shear.  It is the same type of process, wherein a long cut is made in a piece of metal.
  • The process of stamping is similar to punching.  The difference is that the material is not penetrated and a hole is not put in the metal.  Instead, the portion that is shaped by the die is raised.
  • Another popular process in metal design is the use of welding in order to join two pieces of metal together.  The process varies depending upon the types of metal being used.
  • Additive technology. The use of 3D printers is becoming more popular as part of the design process that is referred to as additive technology.  These printers allow anything to be printed directly on the material being used, be it plastic or metal.

When deciding which process to use, it is best to find the one that will not slow down production and one that will not create overproduction either.


Which metal fabrication process is best for your business?

As with any production business, you want to keep quality high and costs low.  When it comes to metal fabrication, the best way to do this is through volume control.  With the advent of the assembly line, cheaper and faster became the norm.  However, that is not always best, particularly if you are in a highly specialized field that requires personalization for each and every order.

Therefore, your company may want to look into high-variation/ low-volume production as opposed to the low-variation/high-volume model currently being used.  The lower the volume output, the better your company can be at tailoring to specific customer demand.  They will also shine when it comes to responsiveness.  However, you do not want to sacrifice quality in order to lower costs.

In order to do so, you must first inform your clients/customers that the metal design may not be immediately available.  Explain to them that you are using the most optimized and appropriate process, but it will take a bit longer to get the parts requested due to the personal nature of the requests being made.

Next, be sure that the process you are using is optimal.  This means that press braking may be the best choice in order to save money.  This is due to the fact that press braking can produce parts more efficiently and at a lower cost than roll forming.  In fact, roll forming could cost thousands of dollars to complete. Therefore, when combined with a turret, press braking can manufacture small quantities of parts with fewer tooling costs than roll forming.

Additionally, the parts that you use should be standard and replaceable.  Otherwise, your process will become obsolete quickly and you will be spending additional funds to find parts that fit into your system.

By using processes suited to low volume production, both your prototype and your production units can have similar components and materials.  This, therefore, enables performance testing to be done early along with preliminary verification and validation exercises.  This, in turn, reduces the surprises that can show up in first few completed units.

However, if you are in high production mode, it is best to use roll forming and stamping because the cost per piece for set-up and labor costs should decrease as production levels increase.  Furthermore, companies that fabricate sheet metal products may incur large labor costs when it comes to producing and assembling individual parts. This is due to labor that can add up quickly across each and every production run.

In order to keep costs down, when doing sheet metal design, it is best to use sequential processing and flexible processing equipment.  Furthermore, routings should be simple and the process should have predictable outcomes.

Finally, the design of the facility, including work stations, equipment placement and staffing should be flexible in order to accommodate changing needs and requirements within the facility.  Being able to reconfigure the work environment as needed, is as critical as the processes, products and staffing levels in creating a economical final product.

Maximize your Denver welding potential

When you need something to be built for you company, it is incredibly important that you are able to have something built that is going to be exactly what you were looking for, be of the highest possible quality and be built in the right ways so that you don’t have to worry about it later on. Of course there is always going to be a difference in what kind of product you can expect to get depending on what the product itself is, what kind of materials you are planning on making the product out of and what you are going to use it for. This is something that you and the rest of your company can go back and forward on and try to figure out what the best option is going to be and how you might reach that goal that you have set out for yourselves.

While each project is different, when it comes to metal working and metal fabrication, one of the best in the business that you can find is going to be Denver Weld of course in Denver, Colorado. Denver Welding and Research makes all different kinds of custom metal goods, all of which live up to the highest standards of quality for any company or individual who wants to be sure that they are getting the best possible metal working and material out there.

Denver WeldingWhen it comes to metal fabrication, the team at Denver Welding and Research can handle every part of the project. They have a varied staff that cover all of the aspects of what is needed with a metal working project such as designers, fabricators, welders, shop hands, managers and laborers. No matter what kind of project that you want to set up and build, no matter how big or how small, how simple or how complex, the metal fabrication team at Denver Welding and Research can make it a reality and have your project come out exactly like you hoped.

There is not just one kind of metal fabrication that they do at Denver Welding and Research either. Over the years that they have been working together, clients have come to them with all different sorts of ideas and projects including metal tables, doors, brackets, staircases, cabinets and even a solid metal guitar. With such talented metal designers and metal fabrication experts, there is nothing that they can’t do at Denver Weld and Research. All you have to do is come up with ideas on what you want and then the team at Denver Weld and Research will start putting all of the pieces together and starting to figure out how to best go about the process so that in the end you are going to walk away with the very best metal fabrication that is going to both make you incredibly happy as well as keep you happy for many years to come. Contact them to get things started and see what you can do with the right Denver welders there to help you out.


What you can do with a Denver welding company

When it comes to manufacturing different things for your company, there are a lot of options out there and a lot of possibilities that you have to go through in order to try and find the one that is going to end up serving you the best and making you the happiest. There is not really one answer though that is going to work for everything that you could need. The best way to do something is highly dependent on what it is that you are trying to build and what your intentions are for the product afterwards. While there is not one single best answer, there are a lot of good answers. One of these is to have a custom Denver welder build you whatever it is that you are looking for. Getting help from a Denver welder like Denver Welding and Research is a great idea because metal is one of the strongest and most durable materials that you could possible use to build whatever it is that you are looking to build. Each welder is going to do things a little bit differently and possibly come out with a slightly different product but if you find a high quality welding company like Denver Welding and Research, you can in the very least make sure that you are going to be able to have the whole project taken care of in one place without any problem or fuss.

Denver Welding This is because when it comes to some of the bigger and more established metal fabrication companies, they have everything that they need from first design to final product all under one roof. For the metal fabrication company Denver Welding and Research, they have the whole thing from A to Z right there so they can build anything that you could possibly want quickly and with some of the best quality that you could possibly ask for. At Denver Welding and Research they have the raw materials for any project that you can have and if they don’t have enough they can have it ordered in just a day or so. They also have the 3D modeling and design tools so that they can design anything from the simple to the incredibly intrigue and complicated. Then they have all of the cutting and grinding tools that they need to create any kind of angles, hinges, sheets of metal or anything else that you could need for your project. After everything is cut and grinded down, it goes on to machining, forming, welding, and finishing. Then the last steps for the metal fabrication specialists are the final coating, assembly and packaging it up and sending it to you. When you have all of the things that you need under one roof like the metal fabrication specialist at Denver Welding and Research do, you can be sure that you are going to be able to get exactly what it is that you are looking for without any major hassle or confusion for having to send your project back and forward between different places for different things.


Purchasing Your First Welder

Buying your own welder for the first time can be a little overwhelming. Do wish to get creative and practice different welding patterns, want something this handy in case when it is really needed, do you like fixing up some old stuff which others see no value in anymore, you may also seek to open your own small welding service in your neighborhood for those who need it. No matter can your interests are at hand, whether you are a pro at welding, a learning novice, or looking to get started on the learning to weld. Here you can know how to choose a welder.

Metal Fabrication

Weld Design

Now you should know that there is not one welding process which can be applied in all situations. You should also know that each different welding process has its advantages. Once you find out about those advantages, it will be easier for you to choose a welder to get. If you are new to the process, you should take note of these advantages unless you are already a pro and know what you are doing.

The first weld process is stick welding. This process of welding is probably the most popular and makes use of an arc welder where there is electric current that flows through the metal and welding stick. This current is known as an arc-welding electrode. Stick welding is effective in creating bonds between dirty or rusted out metal. The limitation on arc welding is the metal is no thinner than an 18-guage, the rod needs to be charged frequently, there is a large spatter, and the welds require cleaning. The difficulty in stick welding is that you need to know how to maintain the arc itself. The welder can makes use of a direct current, an alternate current, or both making it very economical. Hobbyist, farmers, and home maintainers prefer stick welding.

The next one is MIG welding. This makes use of a wire welding electrode that is on a spool which goes at a constant speed which the welder pre-selects. An electric current runs through the metal base to the wire which creates an arc. The product is a weld that has high strength and looks great too. This means there is no need to clean the weld. It is easy to use MIG welding and it is a clean weld too which can be used on both thin and thick metal plates.

Now let’s go to Flux-Cored Arc welding which is a variation of the previously mentioned MIG welding. The process is quite similar only that flux welding does not need to have a shielding gas. This welding process is common in construction due to the fact that it is portable and can be done fast.

The last one is TIG welding. This process makes use of a tungsten electrode which is non consumable in order to create the weld. Usually argon is used as a shielding gas so that the gas around the environment won’t contaminate the welding process.

Now that we have learned about the different welding processes, you can decide which you prefer and buy a welder to suit it.

Starting Your Own Welding Business

Starting your own welding business can be just like starting any other type of business. But just like starting a regular business, it will be a challenge and focusing on welding in your own business will have its own set of ups and downs. When you start your own business there are some key points you will have to focus on. You should be able to get in some customers to get the business running, know how much to charge your customers (not too high or too low), and prepare all the equipment which will be used in your welding business.

Denver Welding

Metal Weld

Now let’s look at how you will be able to get some customers. One trick you can try is going to a number of machine shops and leaving them your business card. But don’t just stop there, along with your business card, leave a sample work. This sample work doesn’t need to be well done or performed by pro welders. The point of this sample is to impress people and make sure they remember you. Because if you just leave the shop your business card, chances are they will forget about it and throw the card away. Your sample works can be made out of regular items like a can or small razor. Be resource and creative.

Once you are good with slowly marketing your welding business, let’s go to how you are going to price the work done by your business. This is probably one of the biggest challenges when it comes to starting a welding business. It is advised that you will set a minimum which will be the basis for other jobs. You can start by charging 30 dollars for a job that took 5 minutes to do. You may even set out this price on a big sign to call out to customers and point out other shops which could be charging more than is set.

When you have the prices for your word cut out, you should start getting some equipment ready to use. If you don’t have any equipment, how are you going to be able to service your customers? There are different methods of welding and not one of them can actually work well in all types of situations. The most common method of welding out there is stick welding so when you are looking for some welding equipment you may want to start with that. From there you can look into other machines once you have generated enough revenue. Take note you will also have to be spending for materials which can be consumed. So there is a constant flow of costs. These consumable materials include the gas, some sanding discs, and wiring. You will also want to get a good welding table to work on.

Now that you have read about the key points in starting a welding business, go one and start working on your own. As you run your business you will find out more on what it takes to keep a welding business running. Don’t forget to get a good staff.

Sheet Metal Design Contributes to Everyday Living

Sheet metal is one of the most common objects that can be seen around us on a daily basis. Everyday means of functioning and operating as a society really depend heavily on the use of sheet metals. Sheet metals are essentially formed from the obvious material, metal. Metal is melted down and formed through a process into aSheet Metal Design thin and flat piece. These pieces can then be molded and bent, so to speak, into many different shapes and styles. Sheet metals will vary in their thickness depending on the purpose they are to service. The process of forming sheet metal is very common because it can utilize the many other metals available today. These metals can be copper, steel, tin, titanium, brass, aluminum as well as silver, platinum and gold.

Because sheet metal design can completed with different types of metals, the overall design can also then be produced with a varying thickness. The options are endless and so are the industries that rely on sheet metal design.

  • Construction. Clearly the construction industry is a strong advocate of sheet metal. Without the use of sheet metal, it would be very difficult to build durable structures.
  • Aerospace. We all rely on on airplanes to get from point A to point B. Even satellites and space stations use it.
  • Medical and pharmaceutical. Medical table are common examples of how this industry uses sheet metal. The non-permeable material of steel is essential to a germ free environment.
  • Electronics. Sheet metals are vital for electronics, such as computers. It plays a part in the reduction of static shock.
  • Food services. Similar to the clean features mentioned in the medical uses, food service companies utilize the process of sheet metal to help build much needed refrigeration devices.
  • Military. Protection and durability are aided by the use of sheet metals
  • Automobile. Similar to the military, cars and trucks rely on sheet metal design to create their safe and appealing structures.

This is by no means a complete and thorough list. There are many uses and reasons why sheet metal is so vital to the operations of daily living and luxuries. Fortunately, sheet metal design contributes to even more particular benefits that make living more comfortable and enjoyable. It also helps reduce many excessive needs of welding and assembly because the sheet metal is designed specifically to bend at various points in order to meet the needs of the overall product. This is where a professional metal fabrication company can really make a difference. Sheet metal design requires exceptional skill and experience in order to create an effective product through sheet metal design.

The experts at Denver Welding & Design are known for their accurate and creative capabilities when it comes to sheet metal design and other custom fabrications. Considering the creating of a given device or product takes significant planning, expert fabricators will spend a considerable amount of time just preparing for the build. This design process is accomplished by many quality fabrications through the use of computer modeling software and employing the latest processes of fabrication.

The Process Behind Metal Fabrication

We have all heard the term, but not many of us actually know or understand the process that is involved with metal fabrication. Most of the machines and buildings, or free standing structures, are results of the metal fabrication process. This process has been around for generations, and for good reason. It is a very beneficial aspect of how people are able to live and accommodate the needs of everyday living, and modern living at that. The structures and pieces of equipment that are built through metal fabrication utilize a variety of raw materials. The most common forms of raw materials are plate metals, formed metals and casted metals. Parts of the fabrication process involve terms such as cutting, machining, welding and forming. All of the specific processes really depend on the scope of the project and the objectives it is needed to fill.

A common example of a project that metal fabricating companies will complete is the building of structural frames, heavy equipment and vital additions to buildingsMetal Fabrication and machines. Just about every single structure present today is built with a system of beams and poles. These systems create the structure that serves as a much needed foundation for a building. The safety and longevity of a building relies on the proper placement and design structural frames. Frames which are produced and placed together through the process of metal fabrication and welding.

May qualified metal fabricating companies will also specialize in custom welding and fabrication. This aspect of metal fabrication can consist of an entire project or just focus in on a specific element or component of a project. Custom fabrication is like any other custom service. It is unique and specialized for the customer. Creating a custom piece of material or a custom product relies heavily on the skill and experience of a fabricating professional. This ability of a skilled fabricator and welder to complete a custom project accurately is their attention to detail before the actual construction begins. The planning and design prep for any custom project is a vital step that must be taken carefully and with steadfast knowledge. Many professional manufacturers will use the assistance of a computer-aided design system in order to effectively conceptualize the logistics of a project and capture any areas that may be compromised during the production process.

Metal design and custom welding also play key roles in the process of customization. Depending on how large or small a project is depends on the extent of the sheet metal design and types of welding that will need to occur. Fortunately, the sheet metal design process has made the custom fabrication process a little bit less time consuming because it allows for needed manipulation of metals that otherwise would require a complex welding process.

The metalwork industry is one of the most important and necessary industries to exist. This is because basic human operations begin with the solutions provided by metalworking professionals. These solutions are what make innovations and modernizations throughout societies possible.