What is Sheet Metal Box Fabrication?

Sheet Metal Box Fabrication

Being a quality-focused supplier, manufacturer and exporter, KDM is offering a first-rate grade sheet metal box fabrication to our customers.

The offered unit are making use in assembling mechanical, electrical and automobile machines.

These sheets are suited inside machineries and engines to help their smooth operation.

To design and fabricate this KDM sheet metal box, our top engineers have used an advanced machinery and quality approved metal sheet at our latest infrastructure facilities.

KDM sheet metal box fabrication is highly recognized for its robust construction, high strength and durability.

At KDM, we support our vast experience with your specifications across our resource and manufacturing base to develop, design, deliver and manufacture precision tools, molds and dies for molded rubber parts, molded plastic part, assemblies, sheet metal components and finished product.

For more than 10 years, KDM is engaged in manufacturing, supplying and exporting sheet metal box fabrication in order to satisfy various demands of our customers in China.

KDM is involved in providing a wide array of sheet metal box fabrication.

These sheets are constructed by our skilled engineers and been rigidly tested in various parameters.

This could ensurethe compliance with the quality industry standards. Our range of sheet metal box fabrication is being deal to all our customers throughout the world.

KDM sheet metal box fabrication easthetically designed and fully engineered for their higher performance and durable life.

In addition to this, the sheet metal box fabrication is rigidly tested with various quality parameters in order to have a flawless range at the end user.

KDM got an excellent satisfaction to found ourselves as one of the popular manufacturers and supplier in China who deals in flawless grade products.

KDM sheet metal box can get in wide variety of specification.

The offered products are manufactured by using advance machine technology and best quality unit guaranteed by our professional team.

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Each and every KDM sheet metal box fabrication is reliable to use, flawless finish, portable size and sturdy design.

Contact us now! We have a professional sales team who provide free quotes and CAD drawings.

They are always ready to response any quotation or question.

Sheet Metal Box Fabrication: The Ultimate FAQ Guide

If you are thinking of any form of sheet metal box fabrication, this guide offers perfect solution you have been looking for.

Whether you want to learn about different types of metal sheets, fabrication techniques or any process – you will find everything right here.

Keep reading.

What Is Sheet Metal Box Fabrication?

Sheet Metal Box Fabrication can be described as a series of processes that are aimed at changing the original shape of a sheet metal.

The desired product is usually a box with the sheet metal undergoing procedural and manufacturing steps that produce the desired product.

sheet metal box

What Is The Benefit Of Using 3D Laser welding Sheet Metal Box Fabrication?

Welding using 3D Laser has proven to be faster than conventional MIG Welding and even much faster than TIG Welding.

3D laser welding sheet metal box

Metal parts are precisely fused using concentrated energy which is extremely aesthetic and very strong.

This means that better products are fabricated but at a very low cost. Its benefits are:

i. It is very fast and extremely efficient thus reducing the fabrication lead time.

ii. The joints created by 3D Laser welding are very strong compared to the ones from manual welding.

iii. It reduces the necessity of finishing or any form of post-welding grinding.

iv. It is very cost effective since it reduces the labor costs and cuts the lead-time.

Which Tools Are Used In Sheet Metal Box Fabrication?

The tools and equipment required for Sheet Metal Box Fabrication include:

• Spot Welder/3D Laser Welder
• Measurement Ruler
• Bar Folder (optional)
• Scratch Awl
• Sheet Metal Break
• Aviation snips
• Foot Shear
• Ruler and scribe
• Center punch

The materials required are:

• Sheet Metal (gauge will depend on design specifications)
• Sand paper
• Layout Fluid (optional)
• Surface Finish materials
• Squaring foot shear

What Are The Different Welding Techniques In Sheet Metal Box Fabrication?

Choosing the appropriate welding technique and filler process can greatly assist in preventing warping and burn-through.

The different type of welding techniques applied in Sheet Metal Box Fabrication include:

Fit-up And Joint Design

This type of technique is mainly used to weld thin metals that require a tight fit-up.

Poor welding can create a hole if the two joined parts do not touch each other hence cannot absorb heat.

Rework can be avoided by redesigning the parts containing joints to endure additional heat. Areas that don’t need a solid weld bead can use a plug weld during welding to ensure efficiency.

Skip Welding

When heat is unevenly distributed while welding, warping and distortion occurs destroying the parts that are to be joined.

Heat should be distributed as evenly as possible to reduce such occurrences.

Skip welding technique efficiently accomplishes this by creating a series of stich welds or recurrent welds.

Backing Bars

A backing bar can be placed in contact with a heat-affected zone for faster dissipation of heat beside atmospheric cooling.

A simple way of doing this is clamping a simple metal bar (normally aluminum or copper for faster dissipation) behind a weldment.

How Does TIG Welding Compare To MIG Welding In Sheet Metal Box Fabrication?

Metal Inert Gas (MIG) welding can be easily performed compared to Tungsten Inert Gas (TIG) welding. Many automated systems in the current industry prefer the use of MIG welding due to its simplicity.

The two methods can be applied in Sheet Metal Box Fabrication welding but thin sheet metals are better welded using TIG welding.

TIG welding sheet metal box

 Very thick sheet metals like structured steel are best welded using MIG welding.

Because the power of the TIG welding can be lowered substantially to avoid welding through, it is solely used on thin sheet metal boxes.

When it comes to speed welding, MIG welding is the fastest because feeding the electrode is done automatically.

MIG welding sheet metal box

How Is Automated Sheet Metal Box Fabrication Using Software And CNC Carried Out?

The major design steps used in automated Sheet Metal Box Fabrication are as listed below:

a. The client submits information in form a PDF,3D SAT, DWG or STEP File. Sample copies or paper drawings adapted to the client’s project can also be submitted.

A 3D model is initially generated to confirm the fit for the various box assembly parts conform. The client has to approve the 3D Box drawing and specifications in order for the production to start.

b. Developed blanks are then extracted from the ‘unfold’ design of the model 3D software box creating a 2D Blank.

The bend allowances of the sheet metal gauge are also factored in depending on the applicable specific part

This eliminates the need to test sample parts because the software can carry out such trials.

c. The sheet blank is then cleaned with focus on the corner notches that may affect the CNC Tooling.

All face details should be the same as the 3D Model with any additional inspection relevant to the fabrication added.

d. The flat sheet metal is then punch pressed using a CNC punch tool with the least number considered efficient.

Removal of the Sheet metal component from the sheet can be through hand removal, complete punch out or tagging its corners.

e. To achieve the desired sheet layout, the sheet metal part is CNC nested to establish the component best fit.

Small parts are punched from gaps while odd shaped parts are fitted together.

This saves cost as material wastage is minimized.

f. The software then confirms that no individual sheet metal part is overlapping with another or with the CNC tooling.

The CNC nested sheet should strong enough during fabrication and hold together while being punched.

g. An order text that leads the CNC fabrication is generated and they can be controlled.

This is mainly important if the box design has tapped plunges, dimples or louvres.

The CNC head can damage them therefore they are after all other holes have been cleared.

h. The verification of the fabricated box is then carried out on the software screen before machining starts. Correction of any sheet metal strange movements is rectified here.

This creates an optimum punching line for use during fabrication.

i. The code needed for the punch press are generated automatically from the ‘blocks’ on the sheet metal.

This instructs the CNC where to punch and what tool to use while punching.

j. The final fabrication occurs after punching. Processes like de-burring, bending and welding are carried out on the sheet metal.

The final product is then cleaned and powder coated. The sheet Metal Box Fabrication is now complete.

What Are The Advantages Of Sheet Metal Box Fabrication?

Various factors have to be considered when deciding the best material to use for fabrication of sheet metal box.

Evaluation has to made on the materials strength under stress and subjected to vagaries of weather over time.

Some of the advantages of Fabricating Boxes with Sheet include:

Strength And Durability

One of the main advantages of Sheet Metal used in Box fabrication is its strength and durability.

Parts fabricated from sheet metals can endure extreme heat and pressure compared to the ones made of plastic.

Besides that, materials such as surface treated steel, aluminum and stainless steel are resistant to wear and tear.

They are also unaffected corrosion and extreme external pressure unlike plastics which cannot hold up that efficiently with time.

Sustainability

Metals are the most sustainable materials compared to any other form of material.

The fact that metal is a naturally occurring resource makes it strategic both economically and environmentally.

If the Sheet Metal Box Fabrication parts are no longer needed, they can be made into other parts hence recycled indefinitely.

Recycling plastics has a limited ability and are hard to safely dispose when their need expires.

Malleability

Besides being durable and strong, Sheet metals used in box fabrication are also easily malleable.

Various shapes and sizes can be achieved when the right equipment is used while retaining its structural integrity.

They also possess the ability to be stretched and compressed devoid of cracking or breakages.

When fabricating, the design only allows for a very specific shape and changing the part can prove expensive.

Cost-Effectiveness

The most economical choice of material for fabrication is sheet metal since the cost of tooling plastics is expensive.

The overall cost reduction and reduction in material waste has made it the perfect material for many companies.

The lifespan of a material together with its durability are highly considered when valuing the material costs.

Having a cheap material does not translate to savings I its cost since it will not last and may require constant maintenance.

Replaceability

A major advantage of fabricating boxes using sheet metal is that parts can be replaced very easily.

If the box is made from assembling various individual parts, the affected component can be removed and replaced.

Money is saved when the entire assembly is not touched during a single component repair. This method can also give room to upgrades or any other necessary modifications.

How Do You Prevent Burn-Through And Warping While Welding In Sheet Metal Box Fabrication?

The flaming torch should not be woven or whipped if burn-through and warping are to be prevented during welding.

The more time the arc spends on a single spot, the hotter that very spot becomes.

A straight line must always be used while welding while applying the best possible travel speed that is fast.

This ensures a good bead profile is created while preventing burn-through and warping at the same time.

Using the MIG gun’s push technique can also prevent warping and burn-through.

The wires are pointed at the base metals cooler edges instead of pulling the gun which leads the wire directly to the puddles hot portions.

This increases the odds of a burn-through or warping occurring.

What Are The Different Forming Processes In Sheet Metal Box Fabrication?

Sheet Metal Box Fabrication entails various sheet forming processes to choose from.

The available processes are:

i. Roll Forming – this process is suitable for lengthy parts which contain intricate cross-sections.

its production rate is high with well-polished surface finishes.

ii. Magnetic-pulse Forming – this process is mainly used in metal sheets with low strength for bulging, shallow forming and embossing procedures.

Tubular shapes are best produced using this forming technique.

iii. Stretch Forming – large parts containing shallow contours are best produced using this process.

The production quantity is low with high labor costs.

iv. Explosive Forming – extremely large sheets with complex axisymmetric shapes.

It has a low tooling cost with longer cycle times and low-quantity production.

v. Drawing – mainly used in the production of deep or shallow parts having simple shapes.

It has a high rate of production but with a high cost of equipment and tooling.

vi. Peen Forming – it is majorly applied in large metal sheets that have shallow contours.

It can also be applied to straighten parts on a metal sheet due to its high flexibility.

vii. Stamping – it involves a variety of operations that include coining, punching and flanging. Others are embossing and drawing (for production of complex or simple designs).

viii. Rubber-pad Forming – simple and complex shapes can be drawn using this process.

The end product is a sheet surface that contains rubber membranes to protect it.

What Are The Material Types Used In Sheet Metal Box Fabrication?

There are several types of materials that are available and suitable for Sheet Metal Box Fabrication. The major metals available are:

• Steel – all the classifications of steel are well known to possess resistance to corrosion, are very ductile and with robust strength.
• Aluminum – this metal has a very high strength despite being relatively lightweight.
• Magnesium – it has a very low density thus suitable for structures that need stiffness. It is a strong shiny lightweight meal.
• Bronze – this metal ha a very low melting point but very ductile.
• Copper – its easily malleable and very soft with very good electrical and heat conductivity.

Which Factors Should You Consider While Looking For A Sheet Metal Box Fabricator?

Serious research should be carried out on the best company to carry out Sheet Metal Box Fabrication to achieve quality results.

Apart from carrying out the research, other traits of the fabricating company should include:

• How long the company has been operational?
• For how long has the company been fabricating sheet metal boxes?
• What is their client base and how big the clientele is?
• Do they have references of projects they have already worked on?
• What is the industry reputation of the company?
• Are they able to give detailed estimates?
• What are the techniques they apply and materials used?
• How do their market prices compare to their competitors?
• Are they able to install the fabricated boxes after manufacture?
• Are they readily available in the event of problem-solving?
• What is their lead time average from production to delivery?

Which Surface Finishes Can You Apply After Sheet Metal Box Fabrication?

There are several surface finish techniques that can be applied depending on the part requirement.

The Sheet Metal Box is protected from corrosion, dust and extremities of weather.

Some of the finishing techniques include:

Brushing

In this type of finish, defects that appear on the surface of the Sheet Metal box are removed.

The metal box brushed against using a brush in an undeviating way hence a parallel grain is created from that.

Powder Coating

For the sheet metal box to last longer and for aesthetics purpose, powder coating is applied to it.

It is a very good choice because the sheet metal box surface has a hard finish.

Polishing

The outer sheet metal box layer can be eliminated by polishing it.

This also assists in the removal any oxidation layer on the box thus leading to shiny and smooth metal box.

Plating

In this process, a metal layer is used to coat the metal sheet box surface.

This is to improve its look and prevent it from vagaries of weather and corrosion.

What Is Forming In Sheet Metal Box Fabrication?

Forming is described as the process used to bend Sheet Metals during fabrication into the required box shape.

This process involves the use of methods such as coining, roll forming and air bending by the manufacturer to achieve desired results

Why Should You Consider Surface Finishing In Sheet Metal Box Fabrication?

Surface Finishes for Fabricated Sheet Metal Boxes should be put into consideration in the early stages of manufacturing.

Visible flaws may be seen on the surface if a metal finishing is not applied. The finishing improves:

i. Durability: the quality of the fabricated box is greatly improved when sharp edges are removed and safety hazards eliminated.

To ensure maximum durability, the boxes should be properly cured and heat treated well.

ii. Aesthetics: this feature is well utilized if the fabricated metal box is placed around a consumer environment.

Polishing and painting such as finishes will ensure the look of the final product is appealing.

iii. Environmental Protection: sheet metal boxes that do not have a surface finish are exposed to environmental extremities like rain, heat and dust.

Finishing methods makes them resistant to corrosion and other conditions.

What Are Expanded Sheet Metals In Sheet Metal Box Fabrication?

These are sheet metals that are fabricated by cutting slits on a normal sheet metal and then stretched forming several diamond shaped openings in a regular pattern.

Compared to normal metal sheets, they are less costly stronger and very light and allow for free flow of air when used in box fabrication.

Which Types Of Brakes Can You Use In Sheet Metal Box Fabrication?

A Sheet Metal Box Fabrication Brake contains an upper beam with an up and down motion where the metal to be bent is inserted.

The lower beam acts as a stabilizer for accurate bending and is always stationery.

The various types of Brakes are as follows:

i. Straight Bending Brake – this type of brake has the ability to make bends that run parallel to each other.

U-sections and angles can be made using this in addition to completely folding an edge over.

ii. Box Finger Brake – this brake is more adaptable compared to straight brake and can make bends that are not just parallel but at angles to each other.

finger box brake

This ensures that various complex angles can be made using this brake

iii. Combination Brake – this type of brake allows the fabrication of straight bends which are long or others at different angles.

Making straight bends is easy because of its continuous bending edge.

Which Cutting Technique Are Suitable For Sheet Metal Box Fabrication?

Cutting Sheet Metals in Box Fabrication is a very complicated process that heavily relies on the material type used.

The desired final box product design also plays a major role in the cutting process to be used.

The major cutting processes are:

• Waterjet Cutting
• Mechanical Cutting
• Shearing
• Punching

 How Does Bending Compare To Pressing In Sheet Metal Box Fabrication?

Bending, just like the name suggests, is a fabrication process involving the bending of sheet metal centered on a rectilinear bending axis by plastic deformation.

Some of the products produced by this technique include angles, brackets and hinges.

Sheet Metal Box Pressing is a series of processes carried out on the sheet metal that includes drawing and punching, embossing, bending and flanging.

This 3D forming process uses very high pressure (using hydraulic or mechanical presses) on sheet metals to make components having a specific form.

Which Factors Should You Consider When Choosing A Surface Finish In Sheet Metal Box Fabrication?

The following factors have to be considered when sourcing for the best surface finish for the Fabricated Sheet Metal Box:

Type Of Metal

Individual metal types contain various characteristics and chemical compositions.

Aluminum and Titanium are usually anodized while stainless steel looks better with a shiny polish for cleanliness and aesthetic use.

Project Cost

The eventual cost of the fabricated sheet metal box is affected by the metal finish type.

This is because some of the finishes require a lot of labor like bead blasting as compared to polishing which is automated.

Project Complexity

Applying finishing methods in fabricate boxes with bent panels is impossible.

Such projects should be clearly discussed with the fabricator before beginning to ensure all requirements are met.

Project Timeline

Normally, automated finishes take a much lesser time as compared to manual finishes.

Such options should be discussed with the fabricator so as not to affect the lead times of the boxes.

How Do You Conduct Blanking Process During Sheet Metal Box Fabrication Process?

Blanking is the procedure used to produce blanks in Sheet Metal Box Fabrication.

The flat piece of metal that is cut out from the Sheet Metal for Box fabrication is what is called a Blank.

Blanking operations are commonly carried out for bending since pressing usually fabricates its own blanks during production.

The most important procedures carried out during blanking include:

Laser Cutting

This is normally preferred when blanks need to be cut from very large metal sheets.

This method is quick and very precise and has very little effect on the actual metal sheet during fabrication.

Punching

A die and a punch are the primary tools used for punching operations to create holes of various shapes and diameters.

This operation can be carried out in either a combi or dedicated machine with combi sustaining both punching and laser cutting.

Embossing

This stamping process produces designs that are either sunken or raised on the sheet metal surface.

Roller dies that male and female matched can be used to achieve this or alternatively having the metal sheet pass between rolls with a design.

Nesting

This process involves placing the metal sheet for laser cutting in a way that it will save cost and wastage of material.

The design elements are placed very close together and sharing of cutting lines may enhance the process.

At KDMSteel, we help you in all sheet metal box fabrication processes – contact us now.