As experienced sheet metal fabricators, we know that the quality of a weld can make or break a finished product. Welding defects can compromise strength, appearance, and performance. In some cases, they can even lead to complete material failure. That’s why it’s essential to understand what these defects are, how they form, and how to prevent them.

In this guide, we’ll explore 14 common types of welding defects. We will outline their causes, how to avoid them, and the inspection methods used to identify issues before they become serious problems. Continue reading for more information.

What are welding defects?

Welding defects refer to any flaw that exceeds the acceptable tolerance within a welded joint. These imperfections may be visible on the surface or embedded within the weld itself.

They often result from:

• incorrect technique
• poor preparation
• unsuitable materials
• machine misconfiguration (including incorrect current, voltage, or travel speed)

Defects can either be external (visible to the naked eye) or internal (detected only through testing). In some cases welds can be repaired, but in others the fault requires complete removal and re-welding.

Welding defects VS Weld discontinuity

These are essentially the same thing, but one is a more extreme and unacceptable version of the other. Let us explain! A weld discontinuity is any interruption or irregularity in the physical structure of the weld or base metal. It refers to something that is not the ideal or intended weld but doesn’t necessarily mean the weld is faulty. 

A weld discontinuity may or may not affect performance, is not always considered a defect and could be caused by process variations, material inconsistencies, or environmental factors. It’s also acceptable if within the limits defined by welding codes or standards (e.g. ISO, BS EN, or AWS).

A welding defect on the other hand is a type of discontinuity that fails to meet that specified acceptance criteria. It can compromise structural integrity, safety and performance of the weld. Welding defects are considered unacceptable and typically require repair or rejection of the weld.

Common welding defects and how to prevent them

How to detect welding defects

Non-Destructive Testing (NDT)

This helps to identify flaws without damaging the weld, making them ideal for batch testing and quality assurance.

Common methods include:

• Visual inspection
• Liquid penetrant testing
• Magnetic particle testing can be used to detect defects too small for visual inspection
• Ultrasonic testing that uses high frequency sound waves to check the interior and exterior of welded metals.
• Radiographic inspection that uses x-rays to inspect the interior of welds.

Destructive Testing

This is used to push materials to failure for detailed analysis. It helps validate weld performance under stress.

These may include:

• Bend tests
• Tensile strength testing
• Nick break tests
• Acid etching

Different welding methods and techniques

Now we understand a little bit more about welding defects let’s take a look at some of the different welding techniques used to join materials together.

Spot welding

Also known as resistance welding, this method is ideal for stainless steel and similar sheet metals. It uses heat generated by electrical resistance to bond materials without filler. It is one of the most common welding methods for many metal materials. 

Benefits include:

• Speedy transfer of energy
• Efficient use of heat
• Easy to automate
• Fit for a range of industries and applications

MIG welding

Metal Inert Gas (MIG) welding suits thicker materials. A continuous wire feed acts as both filler and electrode.

Benefits include:

• Fast weld times (especially in comparison to TIG welding)
• Low post-weld clean up required
• Low production costs  

TIG welding

Tungsten Inert Gas (TIG) welding offers precision and is ideal for thinner sections.

It uses a non-consumable tungsten electrode and a filler is optional.

Benefits include: 

• High-quality, strong and clean welds
• Better control compared to MIG welding
• High precision for fine detail work

Robotic MIG welding

This is also known as gas metal arc welding (GMAW). This semi-automated process ensures precision and consistency, especially in high volume production. It involves using a robotic welding system rather than a human to carry out the MIG process.

Benefits include:

• Improved safety for the welder
• Consistently high quality results
• Lower long term costs 

Professional welding services at Salamander Fabrications

Here at Salamander Fabrications we are extremely proud to boast a team of specialised welders, along with extensive industry knowledge, which means we are one of the UK’s most trusted providers of welding services. We have completed thousands of projects over the last 50+ years and we are already looking forward to helping you with yours.

Salamander fabrications welding specifications

• EN 15614-1: Specification and qualification of welding procedures for metallic materials. Part 1: Arc and gas welding of steels and arc welding of nickel and nickel alloys.
• EN 15614-2: Specification and qualification of welding procedures for metallic materials. Part 2: Arc welding of aluminium and its alloys.
• EN 9606-1: Qualification testing of welders. Fusion welding – steels.
• EN 9606-2: Qualification test of welders. Fusion welding – aluminium and aluminium alloys.

Contact Salamander Fabrications for more information

If you would like some more information on our welding services, or any of our other services, please feel free to contact us. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer, including our:

• Laser cutting services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.If you liked this blog post you may also like to take a read of – What is Soldering?

By Embryo

Can you paint over powder coating? It’s a question you may be forgiven for thinking is rather random and irrelevant for sheet metal fabricators. On the contrary, this is a question we are asked quite often, and with good reason. Powder coating is an extremely important part of many of our metal fabrication processes. Knowing how to apply it, take care of it, and potentially update or replace it later down the line is important to maintaining the lasting integrity of your product. 

So, before we answer whether you can you paint over powder coating, let’s quickly highlight what powder coating is.

What is powder coating?

Metal fabrications are typically tough and highly resistant to wear. This makes them ideal for demanding applications and environments. However, metals like steel that are prone to rust and corrosion can deteriorate more quickly if exposed to harsh weather or moisture. And we get plenty of that in the UK!

In these cases, powder coating becomes a crucial part of the fabrication process. It is applied electrostatically and cured under heat, which forms a strong finish that adheres very tightly to the metal. It offers a protective barrier that extends the lifespan of the finished product. Even for metals that are less reactive, powder coating adds a resilient layer that helps guard against water, chemicals and UV damage.

Can you paint over powder coating?

Okay, but can you paint over powder coating? Technically yes, but with specialist preparation and materials. Otherwise, you may struggle getting your paint to bond or stick. This is because the methods used to apply the coating (as mentioned above) make it hard to paint over with standard paints and what you could consider the typical painting process.

Success rests in surface preparation, as well as the right choice of primer and paint. Oil based and acrylic paints may work just fine but we would generally recommend using epoxy based paints for the best quality results.

Steps to paint powder coated metal

Before you get started, you will need:

• Masking tape
• Fine grit sandpaper
• Degreasing solution
• Suitable primer
• Chosen paint
• Paintbrush
• Protective gear (overalls, gloves, face mask)

Clean and prepare the surface

Good preparation makes all the difference when painting over powder coated finishes. Begin by thoroughly cleaning the surface to eliminate any dirt, oil or grime that could interfere with paint adhesion. Use a strong degreaser to break down any residue, then rinse the area well and allow it to dry fully before moving on.

Next, use fine sandpaper (180–220 grit) to lightly roughen the surface. The aim here is not to remove the powder coating but to give it a slightly textured finish that helps the primer stick. Avoid heavy sanding, just enough to dull the gloss. After sanding is done, you can use a solvent cleaner to remove any dust and debris.

Apply the primer

Priming is a crucial stage when painting powder coated metal. You’ll need a specialist primer designed to adhere to slick or non-porous surfaces. This forms a strong base for the top layer of paint. Apply the primer evenly and allow it to dry for at least an hour, or according to the product’s instructions.

Choose and apply the right paint

Once primed and dry, you’re ready to apply your chosen topcoat. Select a paint that suits the environment. For example, there are weather-resistant options for outdoor use. Apply two even coats, letting each coat dry thoroughly before applying the next. For best results, follow the drying times recommended by the paint manufacturer.

Other ways to prevent rust and corrosion on metal

• Pick rust resistant metals: Choose stainless steel, aluminium or titanium.
• Maintenance: Regular cleaning removes corrosive salts, acids and pollutants. It also identifies potential repairs too.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Use drying agents: Keep equipment and storage areas free from dampness.

Powder coating services from Salamander Fabrications

Here at Salamander Fabrications, we have a wide variety of paints, finishes and colours available for you to choose from. We utilise GEMA equipment for our powder coating process, which can be carried out manually or with a reciprocating gun/automatic reciprocating gun. We can also utilise a protective two coat system with primer and finishing. Our facilities enable us to accommodate parts up to 3000mm long, 1000mm wide and 1400mm deep.

Contact Salamander Fabrications for more information

We hope we have helped answer the question – can you paint over powder coating? If you would like some more information on our powder coating capabilities or any of our other services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer, including our:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Are you curious about what metals don’t rust? Whether you’re a DIY enthusiast, engineer, or architect, rust resistance is a hot topic in the world of metalwork. Especially in Britain’s famously unpredictable weather! Knowing which metals can stand up to rain, salt, and the test of time is key to building long-lasting, low-maintenance structures, gadgets, and artworks.

We’ve been working in the world of sheet metal fabricators for over 50 years now, so we know a thing or two about metal! From gleaming stainless steel to lightweight aluminium, the world offers a host of metals that shrug off rust and corrosion, each with unique advantages. In this guide, we’ll explain the difference between rust and corrosion, explore why certain metals hold up better than others, and showcase the top 10 rust-proof metals.

What causes metal to rust?

Rust is a specific form of corrosion and is a form of iron oxide. It is the enemy of iron and its alloys, like steel. The science is simple – when iron meets oxygen and moisture, a chemical reaction forms iron oxide, better known as rust. This familiar orange, brown layer is more than unsightly, it also expands as it forms. This puts stress on metal structures, making them brittle and exposing them to the risk of failure.

What makes rust especially challenging in the UK is our climate. We have plenty of rain, high humidity, and coastal salt, all of which accelerate rust formation. And if sulphur dioxide or carbon dioxide are present (in city air or industrial settings) the process is even quicker.

Rust is also permeable. That means even once the surface has rusted, water and air can keep seeping in, allowing the corrosion to fester deeper into the metal. For engineers, homeowners, and fabricators, preventing rust is all about careful material choice and protection.

The difference between rust and corrosion 

Although the terms are sometimes used interchangeably, there’s a crucial distinction between rust and corrosion. Corrosion is the broad term for the gradual destruction of metals due to chemical reactions. Any metal can corrode, though some do so much more readily than others.

Rust, on the other hand, is specific to iron and iron-based alloys. This can weaken anything iron from old garden gates to the Cliff Bridge. Other metals, like aluminium or copper, may tarnish or form their own oxides, but these layers are usually much more stable and protective, rather than destructive.

Top 10 metals that don’t rust

So, what metals don’t rust? Below, we reveal the top ten, detailing why they resist rust, where they’re used, and their key properties.

What makes these metals resistant to rust?

The main secret behind what metals don’t rust comes down to chemistry. Metals like stainless steel, aluminium, and titanium form a thin, invisible oxide layer that acts as a barrier. This protects the rest of the metal beneath from air and moisture.

For others, like copper and bronze, a natural patina forms on the surface. This is a green or brown coating that’s not only attractive, but also keeps out further corrosion. Meanwhile, metals like gold and platinum simply don’t react with air or water, making them impervious to rust.

Galvanised steel takes another route. By coating steel in zinc, it gets a protective shield. Even if scratched, the zinc corrodes first, sacrificing itself to protect the steel underneath. This process is known as ‘cathodic protection.’

When to choose rust resistant metals

The choice of what metals don’t rust should be guided by your project’s needs.

• Outdoor structures: Opt for stainless steel, aluminium, or bronze for railings, sculptures, or signage.
• Marine applications: Bronze and titanium excel in saltwater environments, while galvanised steel offers cost-effective protection for short-term uses.
• Medical and food use: Stainless steel and titanium are biocompatible and easy to sterilise.
• Aesthetic projects: Copper, brass, and bronze provide rich, lasting colours and patinas.
• Electronics: Gold and nickel are invaluable for reliable, rust-free connections.

5 metals that are prone to rust or corrosion

Now we’ve highlighted our top 10 list for what metals don’t rust, let’s take a quick look at some that are on the opposite side of the scale.

1. Iron: Pure iron rusts very quickly when exposed to air and water, forming iron oxide (rust). This is commonly found in structural beams, old pipes, and cast iron items.
2. Carbon steel: An alloy of iron and carbon with little or no protective alloying elements. This is widely used in construction and manufacturing, but will rust rapidly if not coated or protected.
3. Cast iron: Another iron and carbon alloy, even more brittle than steel, and highly susceptible to rusting if left unprotected. Used for manhole covers, old cookware, and some pipes.
4. Low alloy steel: This steel has only minor additions of other elements like manganese or nickel. This offers little corrosion resistance compared to stainless steel. This can be found in bridges, frames, and machinery parts.
5. Wrought iron: Malleable iron with a very low carbon content, historically used for gates and fences. Although it has some natural corrosion resistance compared to pure iron, it still rusts easily if exposed to the elements.

How to prevent rust

• Pick rust resistant metals: Opt for stainless steel, aluminium, titanium, and other metals from our top 10 list, especially for outdoor or marine applications.
• Apply protective coatings: Paint, powder coating, oil, or specialised sealants can prevent moisture from reaching metal surfaces.
• Use galvanised or plated finishes: Galvanising coats steel in zinc, while other metals can be nickel or chrome plated for extra protection.
• Keep metals clean and dry: Regular cleaning removes corrosive salts, acids, and pollutants.
• Consider cathodic protection: Especially in marine or underground settings, sacrificial anodes made from zinc or magnesium help protect key metalwork.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

How to prevent corrosion 

• Choose corrosion free metals: Aluminium and stainless steel are both versatile and eco-friendly choices for a range of environments.
• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Non-metallic coatings: Grease, carbon fibre, plastics, paint, and oil create effective moisture barriers.
• Specialist anti-corrosion coatings: Modern products provide strong, UV-resistant layers that don’t chalk, fade, or require multiple coats.
• Use drying agents: Keep equipment and storage areas free from dampness and check regularly for leaks.
• Regular maintenance: Inspect and maintain all metal items, addressing any damage to coatings immediately.

Contact Salamander Fabrications for your metal protection needs today!

If you would like any more information on how to ensure your metal projects are protected from the elements, please give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

We’re also happy to talk you through any of our services, including our:

• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

If you liked reading this blog then you may like to check out our other post – How to Cut Metal: 10 Techniques to Know.

By Embryo

What is a pure metal in comparison to an alloy metal? Also, ever wondered what the full list of pure metals actually is? You’ve come to the right place for the answer! We like to think of ourselves as more than just a sheet metal company, with over 50 years of industry experience, we believe we know everything there is to know about metal!

So we’ve brought you this handy guide to discuss what a pure metal is, the difference between pure and alloy metals, and a table of pure metals with their associated features and properties. Keep reading for more information.

What is a pure metal and where does it come from?

So, what is a pure metal in everyday terms? In short, a pure metal is an element that can’t be broken down into anything simpler by chemical means. It consists of only one type of atom. They are also known as single-phase metals. Gold, silver, copper, and iron are all examples of pure metals in their natural, unalloyed state. These metals form the backbone of modern civilisation and are found in almost everything, from electronics to cutlery, cars, and coins.

In contrast, alloys like steel, brass, and bronze are born from mixing pure metals together. A dash of non-metallic elements, like carbon, is also often introduced to boost performance in specific applications. But it’s the pure metals themselves that offer the original, distinctive set of characteristics. This includes electrical conductivity, corrosion resistance, and ductility.

The origins of pure metals

Most pure metals aren’t just lying around waiting to be picked up. They are typically locked away inside rocks as ores. Through mining, crushing, and various extraction processes (like smelting or electrolysis), these ores are transformed into the metallic materials we use today.

Major mining operations around the globe dig for metals like iron, copper, aluminium, and nickel to supply the raw materials that keep the modern world turning. Some, like gold and platinum, are far rarer, which makes them precious and often pricey. Estimations of the gold content of the Earth’s crust are in the range of 0.001 to 0.006 parts per million.

What is a pure metal VS an alloy metal?

While pure metals are made up of one element, alloys are blends of two or more elements. These are often designed to make the metal harder, stronger, or more resistant to corrosion and wear. For example, copper and tin create bronze; iron and carbon make steel; and gold and silver produce the luxurious white gold.

Most metal items around us these days are actually alloys. Yet, the unique qualities of pure metals remain in high demand for critical applications.

If you have liked reading this blog so far you should take a look at this one next – What is the Strongest Metal?

Full list of pure metals

To answer the question, what is the full list of pure metals? – Here’s a comprehensive table featuring the most significant pure metals, their properties, real world uses, and where they are primarily found around the world.

For more information like this you can check out our other blog – The Different Types of Metals; Their Properties, And Their Applications.

Unique features and properties of pure metals

So now we’ve discussed what is a pure metal and highlighted the full list of pure metals, let’s take a look at some of their collective unique qualities. Pure metals display a fascinating array of properties that set them apart from their alloyed counterparts. 

Here are a few highlights:

• Conductivity: Silver and copper are world beating conductors, making them essential for most electrical applications.
• Corrosion resistance: Gold, platinum, and titanium hardly ever tarnish or rust. This makes them ideal for jewellery, dentistry, and chemical equipment.
• Strength to weight ratio: Aluminium and titanium are both very strong and incredibly light, revolutionising both the transport and aerospace industries.
• Rarity and value: Gold, platinum and their associated group of metals are highly prized, not just for beauty and rarity, but their use in cutting edge technology.

Key Applications

• Electronics: Copper, silver, and gold wires power circuits and connections.
• Transport: Aluminium and titanium make trains, planes, and cars lighter and stronger.
• Construction: Iron and steel (mainly alloyed, but pure iron is the starting point) are used for beams and girders.
• Jewellery: Gold, platinum, silver, and palladium create stunning keepsakes.
• Healthcare: Titanium, platinum, and silver are used in implants, medical instruments, and antimicrobial coatings.
• Batteries: Lithium, cobalt, and nickel power everything from electric vehicles to mobile phones.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

What is a pure metal without metal fabrication services? A blank canvas for the team here at Salamander Fabrications to work their magic on! In truth and despite their unique qualities, pure metals are rarely used alone for most practical purposes these days. They are either too soft or brittle, too expensive, or outperformed by alloyed alternatives. Most of the metals we work on are from the alloy family of metals.

Whether you’re searching for more info on what is a pure metal, exploring the full list of pure metals, or considering a custom fabrication project, Salamander Fabrications can help. With over 50 years’ experience in the industry, we offer a full suite of services, including:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• Powder coating services

For any queries or bespoke requirements, get in touch via our contact page, call us on 01484 843599, or email sales@salamanderfabs.com. Our expert team are always happy to share their knowledge and help you select the right metal for your project.

If you’d like some more information similar to this you can have a read of our other associated blog – Where Does Metal Come From?

By Embryo

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Wondering how to engrave metal? Want to know if there is a single technique that works for everything, or do different methods suit different projects? If you’re looking for guidance on the full range of options and want to understand the strengths and uses of each, you’ve landed in the perfect spot. Here at Salamander Fabrications, the home of expert metal fabrication services, we specialise in all things sheet metal – a common material used for engraving.

In this guide, we’ll break down the five main ways of how to engrave metal, covering both timeless hand skills and the latest machinery. We’ll explore what makes each method unique, the tools you’ll need, best practices, and what types of jobs each approach is suitable for.

1. Engraving metal by hand

Let’s start with the old faithful and the most traditional method of how to engrave metal. The classic image of an artisan at a workbench springs to mind. Hand engraving has centuries of tradition behind it and is still favoured for intricate jewellery, ceremonial objects, and one off pieces where artistry is prized over speed.

This method is best for softer metals like silver, gold, copper, and brass. It is a time consuming process that demands patience and practice. For batch production or very hard metals, other methods may be preferable. The tools you’ll need include gravers (burins), a ball vice, and sharpening stones.

Hand to engrave metal by hand

1. Sketch or print your design, then transfer it onto the metal surface (using paper, acetone, or a vinyl sticker).
2. Secure the metal piece in a ball vice to hold it steady.
3. Select the right graver for your design and sharpen if necessary.
4. Hold the graver at a roughly 45-degree angle to the metal.
5. Push or glide the graver along the design, using consistent, controlled pressure to etch lines.
6. Rotate the metal as needed for curves and intricate patterns.
7. Brush away any debris and clean the surface after engraving.
8. Apply a protective coating or lacquer if desired, especially for metals that tarnish.

Why choose hand engraving?

• Personal touch: Every mark is unique, resulting in truly individual pieces.
• Perfect for: Bespoke jewellery, commemorative items, fine art, and restoration work.

2. Laser engraving

Laser engraving is now one of the most popular ways to engrave metal in the UK and worldwide. Fast, precise, and repeatable – much like our laser cutting services – it’s the go to choice for modern industrial applications.

For this, you will of course need a laser engraving machine (fibre or diode lasers are common for metal). This method is suitable for most metals, including stainless steel, aluminium, copper, and more. The initial setup cost of running your own laser machine can be high, but running costs are generally quite low. It’s a lot more cost-effective to use a professional service that can handle your project from design through to the final product.

Laser engraving can also be utilised alongside CAD design services to help make designs better and more effective. It allows you to accurately set out what you wish to design and then implement it with high precision and speed. For more information on this, you can check out our other blog – What Are The Advantages of CAD?

How to engrave metal with lasers

1. Prepare and set up your laser engraving machine according to manufacturer’s guidelines.
2. Choose your metal blank and position it securely in the engraver.
3. Load your digital design into the engraving software.
4. Adjust laser power, speed, and other settings to suit your metal type.
5. Begin engraving, following all safety precautions (eye protection, ventilation, safety screens).
6. Allow the machine to complete the engraving, then remove and inspect your piece.

Why choose laser engraving?

• Speed and repeatability: Excellent for mass production and high detail work.
• Perfect for: Promotional items, signage, industrial labelling, machine parts, and complex patterns.

3. Rotary engraving with a power tool

For DIY enthusiasts or workshops that need versatility, rotary engraving with an electric tool (like a Dremel) is a practical option. This method combines the control of hand engraving with the efficiency of power tools. This method works well on most common metals, but harder metals may require specialist tool bits.

For this method, you will need your rotary tool, a range of engraving bits, clamps or a vice. Be mindful, though, the rotary tool technique is less precise than laser or CNC engraving for very fine work. You should also always wear eye protection and secure your workpiece to prevent accidents. Fine metal dust can also be produced, so consider respiratory protection or a dust extraction system too.

How to engrave metal with a rotary power tool

1. Clean your metal item thoroughly with alcohol.
2. Mark out your design using a vinyl sticker, transferred print, or permanent marker.
3. Clamp the metal securely in place.
4. Insert the appropriate engraving bit into your rotary tool (diamond bits are ideal for metal).
5. Set the tool to a lower speed, increasing as needed for your metal type.
6. Carefully follow your design, engraving lines with steady pressure
7. Repeat for deeper marks if desired.
8. Switch off the tool and brush away any metal filings or dust.
9. Polish or clean the area to finish.

Why choose rotary engraving?

• Versatility: Suitable for a wide range of projects and can be done at home.
• Perfect for: Custom tools, trophies, signs, hobbyist crafts, and repairs.

4. CNC engraving

Computer Numerical Control (CNC) engraving brings automation to the process, using computer-guided tools to cut complex or repetitive designs with minimal manual effort. It uses the same CNC technology we use for our Press Brakes and Metal Folding Services.

This technique is ideal for metals such as aluminium, brass, copper, stainless steel, and many others. The tools you will need include a CNC engraving machine, various cutting bits, and the required computer software. You may also use a nylon flap or soft brush to remove burrs and sharp edges and achieve a smooth, professional finish.

This method requires investment in equipment and software, as well as programming knowledge, unless you have a professional team handle your project for you.

How to engrave metal with a CNC machine

1. Securely fasten your metal workpiece onto the CNC machine bed.
2. Choose the appropriate bit (diamond cutter, twist drill, or v-bit).
3. Import your design into the CNC software and set your engraving parameters (depth, speed, etc.).
4. Start the engraving operation and monitor progress.
5. Once finished, use a nylon flap or brush to clean off any burrs or debris.
6. Apply a polish or lacquer for extra shine and protection, if needed.

Why choose CNC engraving?

• Automation: Excellent for high volume production or detailed, repeatable designs.
• Perfect for: Industrial parts, machine plates, serial numbers, and complex artwork.

5. Chemical etching

The last one on our list is not technically engraving but the process is very similar and used to achieve the same results. Chemical etching is a powerful and flexible technique widely used in industry for precise, intricate designs that might be too delicate or complex for mechanical engraving. It’s used for items like circuit boards, nameplates, and fine art.

For this technique, you will need metal blanks, photoresist or acid resistant mask, etching solution (usually acid or ferric chloride), a design stencil, and protective equipment. This requires careful handling of chemicals, proper ventilation, and safety precautions. You must also always dispose of used chemicals responsibly according to local environmental regulations.

The chemical etching process

First, a design is applied to the metal using a photoresist film or acid-resistant mask—this can be as simple as hand-drawn patterns or as sophisticated as photographic transfers. The metal is then immersed in an etching solution, which eats away the exposed areas while the masked sections remain untouched. The duration of etching determines the depth of the design. Once etched, the mask is removed, and the piece is thoroughly cleaned and neutralised.

Why choose chemical etching?

• Intricate detail: Can achieve extremely fine and crisp designs, even on thin metals.
• Perfect for: Electronic components, decorative panels, labels, jewellery, and architectural features.

Discover how to engrave metal and much more with Salamander Fabrications.

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us at any time. 

Our other metal fabrication techniques include:

• Welding services
• Sheet metal fabrication services
• Powder coating services

If you’re considering a metal engraving project, looking for advice on how to engrave metal, or need expert help with laser cutting and fabrication, Salamander Fabrications has decades of experience and the right tools for the job.

Our advanced facilities, skilled workforce, and commitment to quality mean every project gets the attention to detail it deserves. We’re always happy to discuss your ideas and recommend the best approach for your idea, no matter how big or small.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Are you curious about what metals don’t rust? Whether you’re a DIY enthusiast, engineer, or architect, rust resistance is a hot topic in the world of metalwork. Especially in Britain’s famously unpredictable weather! Knowing which metals can stand up to rain, salt, and the test of time is key to building long-lasting, low-maintenance structures, gadgets, and artworks.

We’ve been working in the world of sheet metal fabricators for over 50 years now, so we know a thing or two about metal! From gleaming stainless steel to lightweight aluminium, the world offers a host of metals that shrug off rust and corrosion, each with unique advantages. In this guide, we’ll explain the difference between rust and corrosion, explore why certain metals hold up better than others, and showcase the top 10 rust-proof metals.

What causes metal to rust?

Rust is a specific form of corrosion and is a form of iron oxide. It is the enemy of iron and its alloys, like steel. The science is simple – when iron meets oxygen and moisture, a chemical reaction forms iron oxide, better known as rust. This familiar orange, brown layer is more than unsightly, it also expands as it forms. This puts stress on metal structures, making them brittle and exposing them to the risk of failure.

What makes rust especially challenging in the UK is our climate. We have plenty of rain, high humidity, and coastal salt, all of which accelerate rust formation. And if sulphur dioxide or carbon dioxide are present (in city air or industrial settings) the process is even quicker.

Rust is also permeable. That means even once the surface has rusted, water and air can keep seeping in, allowing the corrosion to fester deeper into the metal. For engineers, homeowners, and fabricators, preventing rust is all about careful material choice and protection.

The difference between rust and corrosion 

Although the terms are sometimes used interchangeably, there’s a crucial distinction between rust and corrosion. Corrosion is the broad term for the gradual destruction of metals due to chemical reactions. Any metal can corrode, though some do so much more readily than others.

Rust, on the other hand, is specific to iron and iron-based alloys. This can weaken anything iron from old garden gates to the Cliff Bridge. Other metals, like aluminium or copper, may tarnish or form their own oxides, but these layers are usually much more stable and protective, rather than destructive.

Top 10 metals that don’t rust

So, what metals don’t rust? Below, we reveal the top ten, detailing why they resist rust, where they’re used, and their key properties.

What makes these metals resistant to rust?

The main secret behind what metals don’t rust comes down to chemistry. Metals like stainless steel, aluminium, and titanium form a thin, invisible oxide layer that acts as a barrier. This protects the rest of the metal beneath from air and moisture.

For others, like copper and bronze, a natural patina forms on the surface. This is a green or brown coating that’s not only attractive, but also keeps out further corrosion. Meanwhile, metals like gold and platinum simply don’t react with air or water, making them impervious to rust.

Galvanised steel takes another route. By coating steel in zinc, it gets a protective shield. Even if scratched, the zinc corrodes first, sacrificing itself to protect the steel underneath. This process is known as ‘cathodic protection.’

When to choose rust resistant metals

The choice of what metals don’t rust should be guided by your project’s needs.

• Outdoor structures: Opt for stainless steel, aluminium, or bronze for railings, sculptures, or signage.
• Marine applications: Bronze and titanium excel in saltwater environments, while galvanised steel offers cost-effective protection for short-term uses.
• Medical and food use: Stainless steel and titanium are biocompatible and easy to sterilise.
• Aesthetic projects: Copper, brass, and bronze provide rich, lasting colours and patinas.
• Electronics: Gold and nickel are invaluable for reliable, rust-free connections.

5 metals that are prone to rust or corrosion

Now we’ve highlighted our top 10 list for what metals don’t rust, let’s take a quick look at some that are on the opposite side of the scale.

1. Iron: Pure iron rusts very quickly when exposed to air and water, forming iron oxide (rust). This is commonly found in structural beams, old pipes, and cast iron items.
2. Carbon steel: An alloy of iron and carbon with little or no protective alloying elements. This is widely used in construction and manufacturing, but will rust rapidly if not coated or protected.
3. Cast iron: Another iron and carbon alloy, even more brittle than steel, and highly susceptible to rusting if left unprotected. Used for manhole covers, old cookware, and some pipes.
4. Low alloy steel: This steel has only minor additions of other elements like manganese or nickel. This offers little corrosion resistance compared to stainless steel. This can be found in bridges, frames, and machinery parts.
5. Wrought iron: Malleable iron with a very low carbon content, historically used for gates and fences. Although it has some natural corrosion resistance compared to pure iron, it still rusts easily if exposed to the elements.

How to prevent rust

• Pick rust resistant metals: Opt for stainless steel, aluminium, titanium, and other metals from our top 10 list, especially for outdoor or marine applications.
• Apply protective coatings: Paint, powder coating, oil, or specialised sealants can prevent moisture from reaching metal surfaces.
• Use galvanised or plated finishes: Galvanising coats steel in zinc, while other metals can be nickel or chrome plated for extra protection.
• Keep metals clean and dry: Regular cleaning removes corrosive salts, acids, and pollutants.
• Consider cathodic protection: Especially in marine or underground settings, sacrificial anodes made from zinc or magnesium help protect key metalwork.
• Environmental control: For valuable metalwork (like classic cars or art), use dehumidifiers, climate control, or silica gel packs to minimise moisture exposure.

How to prevent corrosion 

• Choose corrosion free metals: Aluminium and stainless steel are both versatile and eco-friendly choices for a range of environments.
• Laser treatment: Advanced laser technology can create a non-crystalline surface, increasing resistance to corrosion.
• Non-metallic coatings: Grease, carbon fibre, plastics, paint, and oil create effective moisture barriers.
• Specialist anti-corrosion coatings: Modern products provide strong, UV-resistant layers that don’t chalk, fade, or require multiple coats.
• Use drying agents: Keep equipment and storage areas free from dampness and check regularly for leaks.
• Regular maintenance: Inspect and maintain all metal items, addressing any damage to coatings immediately.

Contact Salamander Fabrications for your metal protection needs today!

If you would like any more information on how to ensure your metal projects are protected from the elements, please give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

We’re also happy to talk you through any of our services, including our:

• Welding services
• Metal folding services
• Sheet metal fabrication services
• CAD design services
• Electro mechanical assembly services

If you liked reading this blog then you may like to check out our other post – How to Cut Metal: 10 Techniques to Know.

By Embryo

What is a pure metal in comparison to an alloy metal? Also, ever wondered what the full list of pure metals actually is? You’ve come to the right place for the answer! We like to think of ourselves as more than just a sheet metal company, with over 50 years of industry experience, we believe we know everything there is to know about metal!

So we’ve brought you this handy guide to discuss what a pure metal is, the difference between pure and alloy metals, and a table of pure metals with their associated features and properties. Keep reading for more information.

What is a pure metal and where does it come from?

So, what is a pure metal in everyday terms? In short, a pure metal is an element that can’t be broken down into anything simpler by chemical means. It consists of only one type of atom. They are also known as single-phase metals. Gold, silver, copper, and iron are all examples of pure metals in their natural, unalloyed state. These metals form the backbone of modern civilisation and are found in almost everything, from electronics to cutlery, cars, and coins.

In contrast, alloys like steel, brass, and bronze are born from mixing pure metals together. A dash of non-metallic elements, like carbon, is also often introduced to boost performance in specific applications. But it’s the pure metals themselves that offer the original, distinctive set of characteristics. This includes electrical conductivity, corrosion resistance, and ductility.

The origins of pure metals

Most pure metals aren’t just lying around waiting to be picked up. They are typically locked away inside rocks as ores. Through mining, crushing, and various extraction processes (like smelting or electrolysis), these ores are transformed into the metallic materials we use today.

Major mining operations around the globe dig for metals like iron, copper, aluminium, and nickel to supply the raw materials that keep the modern world turning. Some, like gold and platinum, are far rarer, which makes them precious and often pricey. Estimations of the gold content of the Earth’s crust are in the range of 0.001 to 0.006 parts per million.

What is a pure metal vs an alloy metal?

While pure metals are made up of one element, alloys are blends of two or more elements. These are often designed to make the metal harder, stronger, or more resistant to corrosion and wear. For example, copper and tin create bronze; iron and carbon make steel; and gold and silver produce the luxurious white gold.

Most metal items around us these days are actually alloys. Yet, the unique qualities of pure metals remain in high demand for critical applications.

If you have liked reading this blog so far you should take a look at this one next – What is the Strongest Metal?

Full list of pure metals

To answer the question, what is the full list of pure metals? – Here’s a comprehensive table featuring the most significant pure metals, their properties, real world uses, and where they are primarily found around the world.

For more information like this you can check out our other blog – The Different Types of Metals; Their Properties, And Their Applications.

Unique features and properties of pure metals

So now we’ve discussed what is a pure metal and highlighted the full list of pure metals, let’s take a look at some of their collective unique qualities. Pure metals display a fascinating array of properties that set them apart from their alloyed counterparts. 

Here are a few highlights:

• Conductivity: Silver and copper are world beating conductors, making them essential for most electrical applications.
• Corrosion resistance: Gold, platinum, and titanium hardly ever tarnish or rust. This makes them ideal for jewellery, dentistry, and chemical equipment.
• Strength to weight ratio: Aluminium and titanium are both very strong and incredibly light, revolutionising both the transport and aerospace industries.
• Rarity and value: Gold, platinum and their associated group of metals are highly prized, not just for beauty and rarity, but their use in cutting edge technology.

Key Applications

• Electronics: Copper, silver, and gold wires power circuits and connections.
• Transport: Aluminium and titanium make trains, planes, and cars lighter and stronger.
• Construction: Iron and steel (mainly alloyed, but pure iron is the starting point) are used for beams and girders.
• Jewellery: Gold, platinum, silver, and palladium create stunning keepsakes.
• Healthcare: Titanium, platinum, and silver are used in implants, medical instruments, and antimicrobial coatings.
• Batteries: Lithium, cobalt, and nickel power everything from electric vehicles to mobile phones.

Contact Salamander Fabrications today for your sheet metal fabrication needs! 

What is a pure metal without metal fabrication services? A blank canvas for the team here at Salamander Fabrications to work their magic on! In truth and despite their unique qualities, pure metals are rarely used alone for most practical purposes these days. They are either too soft or brittle, too expensive, or outperformed by alloyed alternatives. Most of the metals we work on are from the alloy family of metals.

Whether you’re searching for more info on what is a pure metal, exploring the full list of pure metals, or considering a custom fabrication project, Salamander Fabrications can help. With over 50 years’ experience in the industry, we offer a full suite of services, including:

• Laser cutting services
• Welding services
• Metal folding services
• Sheet metal fabrication services
• Powder coating services

For any queries or bespoke requirements, get in touch via our contact page, call us on 01484 843599, or email sales@salamanderfabs.com. Our expert team are always happy to share their knowledge and help you select the right metal for your project.

By Embryo

Welcome to our definitive guide on how to cut aluminium, brought to you by the team here at Salamander Fabrications. We’re here to help with your project in any way that we can, whether you need a sheet metal contractor to help facilitate your project, or just some tips and advice on how to cut aluminium sheet. 

Aluminium’s lightweight strength, corrosion resistance, and versatility make it an extremely popular material. It is used in everything from garden furniture to commercial vehicles and architectural features. But its unique combination of properties also means that knowing how to cut aluminium accurately and efficiently is essential, whether you’re a DIY hobbyist, tradesperson, or working on an industrial scale. 

In this comprehensive guide, we’ll discuss the best ways to cut aluminium sheet, the specialist tools and techniques available, and the fabrication processes that ensure your finished product looks and performs as it should.

Techniques for how to cut aluminium sheets

Aluminium sheets are available in a huge range of thicknesses, from ultra-thin foil to sturdy multi-millimetre plates. When it comes to the methods of how to cut aluminium sheet, the one you choose will depend on several factors. This includes the thickness and type of aluminium, the level of accuracy needed, and the tools you have at your disposal.

Picking the right technique not only ensures a neat, clean cut but also minimises material waste and reduces the risk of unwanted damage. This is especially crucial for parts that need to look sharp or fit together precisely.

Below, we’ll break down the most effective methods for cutting aluminium sheet, along with expert tips to help you achieve the best possible finish every time.

Laser cutting

Laser cutting services have revolutionised the metal fabrication industry, offering incredible precision and control that simply cannot be matched by manual tools. This method uses a focused laser beam to heat and melt through aluminium sheets along a pre-programmed path.

Advantages:

• Exceptional accuracy for intricate shapes
• Minimal material distortion and clean, burr-free edges
• Suitable for large scale or repetitive projects

Considerations:

• Requires specialist machinery and proper ventilation
• Best suited to lightweight metals and thin to moderately thick aluminium sheets

Ideal for:

• Architectural features
• Bespoke signage
• Detailed brackets
• Any project where tight tolerances or a smooth finish are required

Plasma cutting

Plasma cutting is another powerhouse of metal fabrication, ideal for tackling thicker sections of aluminium or making complex shapes where brute force and flexibility are needed. It works by blasting ionised gas (plasma) at extreme temperatures through a small nozzle, effectively slicing through metal.

Advantages:

• Powerful enough for thick aluminium plates
• Fast, with impressive edge quality for most uses
• Great for irregular or freeform shapes

Considerations:

• Leaves a slightly wider cut width compared to laser cutting
• May require additional edge finishing

Ideal for:

• Industrial fabrication
• Automotive repairs
• Structural frameworks
• Any job involving substantial aluminium profiles

Waterjet cutting

Waterjet cutting harnesses the raw force of high pressure water mixed with abrasive particles to slice through aluminium. This technique is prized for its ability to handle both very thin foils and extremely thick plates, all while keeping the metal cool.

Advantages:

• No heat distortion or structural weakening
• Ultra-precision makes it suitable for intricate designs or small batch work
• Cuts a wide range of thicknesses and alloys

Considerations:

• Can be more expensive due to equipment and abrasive costs
• Requires a skilled operator for the best results

Ideal for:

• Aerospace components
• Decorative screens
• Complex assemblies where material integrity is critical

Hand tools

For smaller projects, prototypes, or onsite adjustments, hand tools remain an important part of learning how to cut aluminium sheet. They require minimal setup and can be surprisingly effective when used correctly.

• Hacksaw: Best for straight cuts in thin aluminium sheets or bars
• Tin snips: Best for cutting curves or intricate shapes in thin aluminium
• Utility knife: Best for scoring and snapping very thin aluminium, especially for ductwork or foil

Power tools

When you need more muscle, power tools are the answer for efficient, repeatable cuts (especially in medium to thick aluminium sheets). You should always wear goggles, gloves, and a dust mask when cutting aluminium.

• Circular Saw: Best for long, straight cuts in thicker aluminium sheet or plate
• Jigsaw: Best for curved or intricate cuts in aluminium
• Band Saw: Best for both straight and curved cuts, especially in thicker stock

Alternative sheet metal fabrication services

Here at Salamander Fabrications, we understand that there’s more to working with aluminium than just cutting. Sometimes, a project needs bending, welding, or other fabrication processes to bring your vision to life. Here’s a quick overview of other essential metalworking techniques.

Welding

Welding services are at the heart of most metal fabrication projects, especially for joining aluminium parts together. Whether you’re building frames, enclosures, or bespoke pieces, welding creates robust, long lasting joints.

Different types of welding:

• MIG Welding: Great for thicker aluminium, providing fast, strong welds
• Robotic MIG Welding: Delivers consistent quality and is ideal for high volume or repetitive work
• TIG Welding: Perfect for thin sheet aluminium or work that demands a clean, attractive finish
• Spot Welding: Used to join thin sheets without filler, common in automotive and appliance manufacturing

Want to know more? Read our detailed blog post on the subject – What Are The Different Types of Welding?

Sheet metal folding

Sheet metal folding is vital for producing parts with bends or angles, and CNC-controlled folding machines ensure every bend is precise and repeatable.

Stand-out features:

• Precision: Allows for exact bends and identical pieces that meet strict quality standards
• Cost-effective: Lowers costs by reducing the need for welding or additional assembly

Coating and finishing

Aluminium’s natural oxide layer makes it resistant to corrosion, but the right finishing or powder coating process can enhance durability and appearance even further.

Popular finishing techniques:

• Powder coating: Creates a tough, colourful finish that resists scratching and UV fading.
• Electroplating: Adds a decorative or protective metal layer which is ideal for high wear or visible components.
• Polishing and brushing: Delivers a high shine or a modern, textured look for decorative aluminium.

Choosing the best method for how to cut aluminium

Selecting the best method for how to cut aluminium depends on your tools, the thickness and alloy of the sheet, and the demands of your project. Hand tools are great for light work, while power tools and advanced machinery offer the accuracy and speed required for larger or more complex jobs.

Don’t forget to clean, deburr, and finish all cut edges for safety and appearance. If in doubt, consult a professional sheet metal contractor. Working with aluminium is as much about experience as it is about equipment.

Contact Salamander Fabrications for more information on our laser cutter – our method for how to cut aluminium

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us any time. The team here at Salamander Fabrications are more than happy to talk through the services we have to offer and share our expertise.

Give us a call on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo

Wondering how to engrave metal? Want to know if there is a single technique that works for everything, or do different methods suit different projects? If you’re looking for guidance on the full range of options and want to understand the strengths and uses of each, you’ve landed in the perfect spot. Here at Salamander Fabrications, the home of expert metal fabrication services, we specialise in all things sheet metal – a common material used for engraving.

In this guide, we’ll break down the five main ways of how to engrave metal, covering both timeless hand skills and the latest machinery. We’ll explore what makes each method unique, the tools you’ll need, best practices, and what types of jobs each approach is suitable for.

1. Engraving metal by hand

Let’s start with the old faithful and the most traditional method of how to engrave metal. The classic image of an artisan at a workbench springs to mind. Hand engraving has centuries of tradition behind it and is still favoured for intricate jewellery, ceremonial objects, and one off pieces where artistry is prized over speed.

This method is best for softer metals like silver, gold, copper, and brass. It is a time consuming process that demands patience and practice. For batch production or very hard metals, other methods may be preferable. The tools you’ll need include gravers (burins), a ball vice, and sharpening stones.

Hand to engrave metal by hand

1. Sketch or print your design, then transfer it onto the metal surface (using paper, acetone, or a vinyl sticker).
2. Secure the metal piece in a ball vice to hold it steady.
3. Select the right graver for your design and sharpen if necessary.
4. Hold the graver at a roughly 45-degree angle to the metal.
5. Push or glide the graver along the design, using consistent, controlled pressure to etch lines.
6. Rotate the metal as needed for curves and intricate patterns.
7. Brush away any debris and clean the surface after engraving.
8. Apply a protective coating or lacquer if desired, especially for metals that tarnish.

Why choose hand engraving?

• Personal touch: Every mark is unique, resulting in truly individual pieces.
• Perfect for: Bespoke jewellery, commemorative items, fine art, and restoration work.

2. Laser engraving

Laser engraving is now one of the most popular ways to engrave metal in the UK and worldwide. Fast, precise, and repeatable – much like our laser cutting services – it’s the go to choice for modern industrial applications.

For this, you will of course need a laser engraving machine (fibre or diode lasers are common for metal). This method is suitable for most metals, including stainless steel, aluminium, copper, and more. The initial setup cost of running your own laser machine can be high, but running costs are generally quite low. It’s a lot more cost-effective to use a professional service that can handle your project from design through to the final product.

Laser engraving can also be utilised alongside CAD design services to help make designs better and more effective. It allows you to accurately set out what you wish to design and then implement it with high precision and speed. For more information on this, you can check out our other blog – What Are The Advantages of CAD?

How to engrave metal with lasers

1. Prepare and set up your laser engraving machine according to manufacturer’s guidelines.
2. Choose your metal blank and position it securely in the engraver.
3. Load your digital design into the engraving software.
4. Adjust laser power, speed, and other settings to suit your metal type.
5. Begin engraving, following all safety precautions (eye protection, ventilation, safety screens).
6. Allow the machine to complete the engraving, then remove and inspect your piece.

Why choose laser engraving?

• Speed and repeatability: Excellent for mass production and high detail work.
• Perfect for: Promotional items, signage, industrial labelling, machine parts, and complex patterns.

3. Rotary engraving with a power tool

For DIY enthusiasts or workshops that need versatility, rotary engraving with an electric tool (like a Dremel) is a practical option. This method combines the control of hand engraving with the efficiency of power tools. This method works well on most common metals, but harder metals may require specialist tool bits.

For this method, you will need your rotary tool, a range of engraving bits, clamps or a vice. Be mindful, though, the rotary tool technique is less precise than laser or CNC engraving for very fine work. You should also always wear eye protection and secure your workpiece to prevent accidents. Fine metal dust can also be produced, so consider respiratory protection or a dust extraction system too.

How to engrave metal with a rotary power tool

1. Clean your metal item thoroughly with alcohol.
2. Mark out your design using a vinyl sticker, transferred print, or permanent marker.
3. Clamp the metal securely in place.
4. Insert the appropriate engraving bit into your rotary tool (diamond bits are ideal for metal).
5. Set the tool to a lower speed, increasing as needed for your metal type.
6. Carefully follow your design, engraving lines with steady pressure
7. Repeat for deeper marks if desired.
8. Switch off the tool and brush away any metal filings or dust.
9. Polish or clean the area to finish.

Why choose rotary engraving?

• Versatility: Suitable for a wide range of projects and can be done at home.
• Perfect for: Custom tools, trophies, signs, hobbyist crafts, and repairs.

4. CNC engraving

Computer Numerical Control (CNC) engraving brings automation to the process, using computer-guided tools to cut complex or repetitive designs with minimal manual effort. It uses the same CNC technology we use for our Press Brakes and Metal Folding Services.

This technique is ideal for metals such as aluminium, brass, copper, stainless steel, and many others. The tools you will need include a CNC engraving machine, various cutting bits, and the required computer software. You may also use a nylon flap or soft brush to remove burrs and sharp edges and achieve a smooth, professional finish.

This method requires investment in equipment and software, as well as programming knowledge, unless you have a professional team handle your project for you.

How to engrave metal with a CNC machine

1. Securely fasten your metal workpiece onto the CNC machine bed.
2. Choose the appropriate bit (diamond cutter, twist drill, or v-bit).
3. Import your design into the CNC software and set your engraving parameters (depth, speed, etc.).
4. Start the engraving operation and monitor progress.
5. Once finished, use a nylon flap or brush to clean off any burrs or debris.
6. Apply a polish or lacquer for extra shine and protection, if needed.

Why choose CNC engraving?

• Automation: Excellent for high volume production or detailed, repeatable designs.
• Perfect for: Industrial parts, machine plates, serial numbers, and complex artwork.

5. Chemical etching

The last one on our list is not technically engraving but the process is very similar and used to achieve the same results. Chemical etching is a powerful and flexible technique widely used in industry for precise, intricate designs that might be too delicate or complex for mechanical engraving. It’s used for items like circuit boards, nameplates, and fine art.

For this technique, you will need metal blanks, photoresist or acid resistant mask, etching solution (usually acid or ferric chloride), a design stencil, and protective equipment. This requires careful handling of chemicals, proper ventilation, and safety precautions. You must also always dispose of used chemicals responsibly according to local environmental regulations.

The chemical etching process

First, a design is applied to the metal using a photoresist film or acid-resistant mask—this can be as simple as hand-drawn patterns or as sophisticated as photographic transfers. The metal is then immersed in an etching solution, which eats away the exposed areas while the masked sections remain untouched. The duration of etching determines the depth of the design. Once etched, the mask is removed, and the piece is thoroughly cleaned and neutralised.

Why choose chemical etching?

• Intricate detail: Can achieve extremely fine and crisp designs, even on thin metals.
• Perfect for: Electronic components, decorative panels, labels, jewellery, and architectural features.

Discover how to engrave metal and much more with Salamander Fabrications.

If you would like some more information on our laser cutting capabilities or any of our other sheet metal fabrication services, please feel free to contact us at any time. 

Our other metal fabrication techniques include:

• Welding services
• Sheet metal fabrication services
• Powder coating services

If you’re considering a metal engraving project, looking for advice on how to engrave metal, or need expert help with laser cutting and fabrication, Salamander Fabrications has decades of experience and the right tools for the job.

Our advanced facilities, skilled workforce, and commitment to quality mean every project gets the attention to detail it deserves. We’re always happy to discuss your ideas and recommend the best approach for your idea, no matter how big or small.

Give us a call if you think we can help you on 01484 843599 or send an email to sales@salamanderfabs.com.

By Embryo