Working with sheet metal isn’t easy, as one wrong move can ruin your entire project. These three tips will help you avoid common mistakes and get better results with your sheet metal work.
Choose the Right Material
The metal you select makes a big difference to both cost and quality. Using standard sizes can save you up to 20% compared to custom cuts. In America, thickness is measured in gauges, while other countries use metric measurements. Carbon steel is usually the cheapest material, with aluminium in the middle and stainless steel being most expensive. But when it comes to working with these metals, aluminium is often easiest and therefore cheapest to manufacture, followed by carbon steel. Stainless steel requires special equipment for thicknesses above 1/16″. If you’re choosing a metal for its look rather than its function, consider using cheaper metals with finishes like powder coating. This can save you a lot of money while achieving similar results.
Use Standard Gauges
Sticking with common metal thicknesses makes fabrication simpler and less expensive. Most sheet metal fabrication services, for example those from dkmsheetmetal.co.uk/, work best with metal up to a quarter inch or 6.35mm thick. Thick metals are harder to bend and sharp bends can cause tiny cracks that weaken the metal. Some bends are impossible to make with standard equipment, which can lead to extra costs and delays. For complex designs, thinner metals are usually better as they bend more easily without cracking or tearing.
Keep Your Design Simple
Smart design choices save time and money. When planning your project:
- Put bends in the same direction whenever possible, as each turn of the metal in the machine adds to your labour costs.
- Use the same bend radius throughout your design if you can. A good rule is to make your bend radius at least as big as the thickness of the metal.
- Avoid small bends on thick material. They’re harder to make accurately and often cause problems. If your design needs bends, think about changing to thinner metal or redesigning those sections.
