As kiosk manufacturers ourselves, Salamander Fabrications is here to give expert insight into the increasingly common question: what is a kiosk?
A kiosk is a metal standalone structure, usually seen in public spaces like shopping districts or the entrance to attractions. The purpose of a kiosk is to provide goods or services to a customer. Sometimes they operate by using automation, like in the case of self-serve kiosks, and sometimes are manned by staff.
In this guide, we’ll take you through all you need to know about what kiosks are, how they operate and how they are made.
The first thing to know about kiosks is that there are two key types you will encounter: manned and self-service kiosks. Let’s explain exactly what each of these kiosk types entails.
Manned Kiosks
These are kiosks operated by a person or persons. This is most commonly the case for catering kiosks, where food is served to customers and sometimes also prepared within the confines of the kiosk, by a member of staff.
Burger vans, street food kiosks and coffee carts are all examples of manned kiosks. You might also find them in other scenarios where human interaction with customers has been selected over automation, for example, in ticketing booths.
Self-Service Kiosks
What is a self-service kiosk? A self-service kiosk, as you can surmise from the name, allows a user to serve themselves. This is usually achieved through an interface such as a display screen and a way for the customer to communicate their choices like a touch screen or pin pad.
Consequently, it will also generally have an integrated payment feature that allows for card or cash payment to be made by the customer at the time of purchase
Self-service kiosks are on the rise globally, in part due to how they can help reduce staffing costs for businesses. Datos Insights reports that from the two years up to 2023 self-service kiosks in the restaurant industry rose by 43%, a clear indication of how the world is embracing self-service kiosks.
What Are the Most Common Categories of Kiosks?
Kiosks provide a wide range of services in our daily lives. We can categorise these into several broad types of kiosks below.
Food Kiosks – As you can imagine, food kiosks allow vendors to sell a variety of foods to customers. This can range from hot beverages to street food.
Catering Kiosks – As with food kiosks, catering kiosks are designed for serving food to customers. The key difference is that catering kiosks are equipped for food preparation within the kiosk itself, whereas some food kiosks simply serve pre-prepared food.
Service Kiosks – This kind of kiosk gives the user a specific service or piece of information. Often this means completing a task – like retrieving tickets or checking into a venue – without the need for human assistance.
Vending Machines – You might not immediately have thought of vending machines as a form of kiosk, but they are. They are typically positioned in public places where people might need what they serve automatically.
Other Enclosures – This category of kiosk includes miscellaneous kinds of enclosures that are defined as kiosks. One example would be digital advertising displays which are thought by some to be a kiosk in that they are standalone structures which exist in public spaces, and provide a visual service to users despite not requiring interaction.
10 Different Examples of Kiosks
Until you start to think about kiosks, you don’t necessarily realise how many you see and interact with in public spaces on a daily basis. Let’s take a look at some of the most common ones, as well as some extremely new developments.
1. Wayfinding Kiosks
These problem-solving kiosks are usually dotted around large venues, often shopping centres, to assist people by providing directions. Using a touchscreen, users can enter their desired endpoint and receive specific map instructions on the screen.
2. Streetfood Kiosks
From pop-up food trucks at festivals to burger vans outside football stadiums, catering kiosks are a key kiosk type. Streetfood kiosks offer the ability to prepare and sell food from inside the kiosk. Most often they are easily transportable so that they can be taken to events to trade.
3. Vending Machines
Vending machines are a popular form of self-serve kiosk. They offer franchise opportunities and can make a great investment when placed strategically. The owner will have the responsibility of stocking them and will need to apply for relevant permits in order to install and run one in the public domain.
4. Temperature Kiosks
This form of kiosk is a new development in the world of kiosks since the Covid-19 pandemic. These stands are often found in airports and offices and allow users to have their temperature scanned to check that they aren’t ill before entering a densely populated space.
5. Coffee Carts
Coffee carts are usually movable catering kiosks that serve hot beverages like tea and coffee. They are often portable in order to be placed in popular areas by the vendors. They are a highly common form of kiosk.
6. ATMs
Did you know that ATMs are a common form of kiosk? They require extremely robust casing and tight conformity to the provider’s design and branding. Take a look at the ATM project we completed for Travelex cash machines.
7. Ticketing Kiosks
While ticketing enclosures are occasionally manned, generally they tend to be self-service kiosks. These kiosks allow users to redeem or purchase tickets, often also printing and dispensing the tickets as well.
8. Mobile Device Charging Kiosks
These kiosks are another modern development in the world of kiosks. They allow users to charge their phones for a fee and are usually found in places like airports or train stations for convenience.
9. Photo Printing Kiosks
Photo printing kiosks are a good example of where a kiosk has replaced the need for a business’s staffing costs. Customers can interact with the touchscreen to select their photos and print them on the spot.
10. Package Collection Lockers
This is an increasingly prevalent example of a completely self-service form of kiosk. Customers pick up packages contained within a metal locker in a public location by entering a release code on the touchscreen pad. This unlocks the locker.
What Is A Kiosk Made From?
Kiosks by their nature serve the public wherever they are needed, so it’s normal for them to be positioned outside in all weathers. This is why kiosks need to be robust. Their manufacture requires skilful design and strong materials. Most often metal is chosen as the material for the outer enclosure of a kiosk.
The Make-Up of a Kiosk
Depending on their function, different types of kiosks will have a variety of designs and features. However, the core makeup of any kiosk can be broadly categorised into the following components.
Enclosure
The whole kiosk will be encased in a robust enclosure, usually made from sheet metal.
Control PC
The control PC is the ‘brain’ of the kiosk managing and controlling its functions. It is the CPU which runs the software for the kiosk and connects to and processes the input from any hardware, such as pin pads.
Screen
In most cases, self-service kiosks will have a screen. Where the kiosk sells goods or services the choices will generally be displayed in the form of a user flow menu.
Peripherals
Peripherals include hardware integrations like pin pads, plastic and metal housing and branding etc.
Thermal Printer
Where receipts are given by the kiosk, a thermal printer will be housed inside the enclosure.
How Is a Kiosk Manufactured?
The requirements for how each kiosk is made will differ depending on the complexity of the design. The standard outline is as follows:
Design phase: At Salamander, we are skilled at taking pre-existing designs that conform to strict brand guidelines and creating them to tight tolerances. However, we can also help you with CAD and CAM design services for kiosks.
Sheet metal fabrication: The metal used in the project will require sheet metal fabrication and then manipulation to create the correct components, using laser cutting and sheet metal bending.
Electromagnetic assembly: Electrical parts are typically put into place within the house of the machine using electromagnetic assembly. This allows us to complete the project with every element where it needs to be.
Make Salamander Fabrication Your Kiosk Manufacturer
As expert sheet metal fabricators, we’re well-equipped to produce kiosks from scratch to excellent commercial standards. We’ve produced large quantities of kiosks and are trusted kiosk manufacturers for large brands across the UK.
If you’re interested in learning about how Salamander can help you produce kiosks quickly and accurately, get in touch with the team today or call us at 01484 843599.
FAQs About Kiosks
Now that we have comprehensively answered the question ‘What is a kiosk?’, here are some extra answers to questions that commonly crop up around the topic.
What does a kiosk mean?
Kiosk is an umbrella term used to describe enclosures which provide goods, services or information to customers. Often they include an interface for ordering and payment, like a touch screen or pin pad in self-service kiosks. The term used to refer to an outdoor pavilion however the meaning has adapted with modern times.
Why are kiosks increasingly popular?
Kiosks allow owners to service customers in a relatively low-cost way. After initial outlay on the kiosk fabrication, they require relatively little input to get started compared to a bricks-and-mortar establishment. For instance, a self-service kiosk will require no staffing costs.
How much does a kiosk cost?
Factors that will influence the cost of a kiosk include the thickness and grade of the materials used to produce it as well as the complexity of the electrical components integrated in the machinery. Every project comes with different requirements, however, we are always happy to get the full details and then provide a clear, no-obligation quote.
If you’re toying with using laser cutting as part of your metal manufacturing process, you might be wondering: Is laser cutting sustainable?
It’s no secret that sustainability is on consumers’ minds and has been an increasing priority in all sectors of manufacturing. At Salamander Fabrications, we utilise custom laser cutting services to meet the needs of our commercial clients, operating fibre lasers specifically.
Consumers being more empowered to find out how their goods are made means that more than ever, people are curious to know what the environmental impact of laser cutting is. So, if you’re interested to know, ‘Is laser cutting environmentally friendly?’, read on. We’ll dive into just how sustainable laser cutting really is.
To find out more about Salamander Fabrications’ laser cutting services, get in touch with our sales team today at 01484 843599.
Why Is Laser Cutting a Sustainable Manufacturing Method?
The key advantage of laser cutting over traditional methods is that laser cutting is highly accurate, especially when operated by experienced professionals who can get the most out of your sheet metal and code extremely efficient laser cutting computer programmes.
To understand why laser cutting is an energy-efficient form of cutting various materials like metal it’s important to understand how laser cutting works. Laser cutting uses thermal heat by focussing a laser beam onto materials to burn through them. This is what’s known as non-contact cutting. This has certain benefits for the cutting process, and in particular, positive implications for sustainability. We’ll take you through exactly how in the next section.
If you’re exploring laser cutting for the first time and would like a more thorough explanation, we dive into the subject by answering the question ‘what is laser cutting?’ in another guide.
The Greener Benefits of Laser Cutting
The laser beam is highly focused, allowing for an enormous degree of accuracy. This accuracy means less wastage. The cuts are clean and precise in most cases.
The way that laser cutting is operated is most commonly through CNC programming and CAD/CAM design. The fact that the designs for the cuts are pre-calculated means that you can get the most out of your sheet metal and create intricate objects.
The majority of the process in most cases is automated. This means that human error is almost entirely eliminated. This dramatically reduces wastage from the results of human error such as cutting imprecisely or scorching.
The laser beam requires less power in order to cut through materials than traditional methods. The reduction in energy expended is a key factor in making laser cutting a sustainable choice.
So, in answer to the question ‘Is laser cutting sustainable?’ – the answer is a clear yes, compared to older methods like CNC cutting. However, when exploring the most common types of laser cutting, we established that while the output from laser cutting is similar, the different laser cutters used to produce these results differ.
They differ in aspects like the fuels they run on, how accurate they are, how energy efficient they are and how often they need to be maintained or ultimately replaced. These are all factors in how sustainable they are.
What Is the Most Sustainable Kind of Laser Cutting?
At Salamander we use fibre lasers instead of C02 lasers because they do not require the same level of gas fuel to run and they are a lot more energy efficient in general. Energy efficiency is one of the key metrics to consider when assessing how sustainable laser cutting is.
What Makes Fibre Laser Cutters the Most Sustainable?
Fibre laser cutting works by delivering a concentrated beam of light through a doped optical fibre. There are several reasons why fibre lasers, compared to other types, are the more sustainable choice. These are key reasons why we opt to use them in our sheet metal fabrication and cutting process, here at Salamander Fabrications.
The reasons fibre laser cutters are more sustainable than other lasers are:
They deliver a strong amount of power for the energy they take to run
They require less energy to run the laser than other forms of laser
They don’t require any gas to run, unlike C02 lasers, for instance
They require little maintenance compared to other lasers and last for a long time
Some lasers that run by utilising gases can release contaminants when they interact with the materials they cut – with fibre lasers these emissions are eliminated as they do not use gas
Is Laser Cutting Sustainable in General?
While fibre lasers might be the most sustainable option when considering all factors involved, laser cutting in general is a much more sustainable option than the traditional methods of cutting metal that are notoriously energy inefficient.
Before laser cutting became prevalent in industrial materials cutting, the main methods of cutting through materials on an industrial scale were:
CNC Cutting
Oxy-Fuel Cutting
Plasma Cutting
Water-Jet Cutting
Mechanical Cutting Machines
All of these methods are far more intensive in their use of energy, as well as other resources like water and gases.
So regardless of which laser cutter you opt for, you’re choosing an efficient and modern method of materials cuttings.
Why It Might Matter to You If Laser Cutting Is Sustainable
If your company is producing or retailing goods containing metal components, the environmental impact of laser cutting should be on your mind. Here are a few key reasons why making your metalworking more sustainable might matter to you:
You are working with a third party who has sustainability commitments you need to adhere to – B Corp registered businesses, for instance, have to adhere to a higher level of transparency and accountability about their business sustainability practices to gain and keep their accreditation
You want to produce goods and demonstrate your commitment to sustainability as a unique selling point to consumers – As McKinsey and Neilson IQ found in their consumer insights report, 78% of consumers say that a sustainable lifestyle is important to them. This research also supports that consumers are willing to pay more for greener products – up to 28% more, in fact.
You have your own business sustainability commitments and want to invest in greener practices – Businesses who make commitments to reducing their carbon footprint can meet their goals by adopting new, more sustainable manufacturing. For instance, by making changes like using laser cutting over higher impact processes.
You’re changing processes in line with carbon reduction targets – As the government starts to target high-energy industries to achieve carbon reduction targets for 2050 many manufacturers are aware that there is increasing pressure to implement sustainable manufacturing processes.
If any of these reasons jump out to you as being beneficial for the future of your metal manufacturing processes, Salamander Fabrications can help you switch to laser cutting. We provide commercial laser cutting services to a wide variety of industries.
Move to Greener Manufacture with Salamander’s Laser Cutting Services
If you’re ready to embrace a more sustainable method of cutting metals and other heavy materials, laser cutting might be the best option for you. Here at Salamander Fabrications, we use fibre lasers for our laser cutting projects. This allows us to operate efficiently and sustainably on behalf of our clients.
We use two Bystronic laser cutters on a 24/7 basis and ensure all production is projects managed and quality controlled by our highly skilled team. If you’re looking for commercial laser cutting services, simply get in touch with the team today.
FAQs about the environmental impact of laser cutting:
We’ve put together some FAQs to help answer some common questions about sustainability in laser cutting.
Does laser cutting use a lot of energy?
The amount of energy used in laser cutting generally depends on which laser you are using. Some will expend more than others. As we have discussed, fibre lasers are currently the most energy efficient option. However, when you compare all laser cutting to traditional methods using heavy mechanical cutting machines, it is dramatically more energy efficient.
Are laser cutting fumes toxic?
This will depend largely on the material being cut. At Salamander the majority of our work, due to being sheet metal fabrication experts, is with metals. The possibility of metal cutting releasing toxins is generally low, except for situations in which the metal has a coating.
Can you reuse the scrap produced by laser cutters?
Yes, the scrap metal produced by laser cutting machines can be recycled. This is an example of a closed-loop system in which waste is almost entirely eliminated.
If you’re contemplating aluminium laser cutting, consider this your complete guide to understanding exactly why and how laser cutting is the right choice in many cases.
Aluminium is a metal with some unique properties that make it a great option for particular industries. Not only is it lightweight, non-toxic, resistant to corrosion and heat as well as a good electrical conductor – it’s also generally considered an affordable metal due to its relative abundance.
Aluminium is a highly reflective metal, making cutting with any laser challenging, as it can cause burning, ruined sheet metal and potential safety concerns for the operator such as eye damage. We advise that inexperienced laser operators never tackle reflective surfaces. However, all of our staff wear protective equipment and are highly trained and able to manage these risks. In fact, fibre lasers mostly use automated processes via programming, eliminating many of these safety risks.
Which industries can benefit most from aluminium cutting?
In a variety of industries aluminium is a go-to choice for parts which require a lightweight, heat-resistant, high-strength and versatile material, hence why it’s sometimes even called the ‘miracle material’. This often means parts need to be made to intricate, finely calibrated specifications. This is why laser cutting aluminium becomes the ideal choice to produce metal parts, as it can quickly produce extremely precise results.
Here are some examples of key industries which can benefit significantly from aluminium laser-cut parts:
Computing – Aluminium is often chosen for computer components due to its lightweight and particular ability to dissipate heat which helps with portability and heat reduction in computers.
Electronics – As with computing, the heat reduction properties of aluminium make it ideal for use in electronic devices with electrical enclosures which require heat sinks and as an electrical conductor.
Automotive and Aerospace – Aluminium is widely used in the transport industry to manufacture lightweight, high-strength components such as chassis and fuselage parts.
Consumer Goods – Aluminium is extremely durable, making it an ideal material for home goods like appliances, decorative accessories and furniture.
Which kind of laser is best for cutting aluminium?
Both fibre lasers and C02 lasers are the two main types that are predominantly used for laser cutting aluminium in sheet metal fabrication. Different businesses will have different preferences based on the thickness and speed of the job at hand.
The benefits of using C02 lasers for cutting aluminium
C02 lasers operate by inciting carbon dioxide molecules to produce a powerful infrared light beam which can be used for metal cutting and engraving.
The key benefit of C02 lasers compared to fibre is their ability to cut thicker sections of metal. This gives them the ability to work on thick metal-cutting projects. While it can produce a powerful laser beam, it operates on gases which must be replenished and is less energy efficient than its fibre counterparts. They are also notoriously finicky machines which require constant maintenance and calibration.
The benefits of using fibre lasers for cutting aluminium
Fibre lasers get their name from the use of optical fibres. They operate by passing the laser beam through fibreglass diodes, which amplify it.
It also has other clear benefits:
Fibre lasers are a strong a precise method of metal cutting delivering a smooth cut
They are also fast, allowing them to tackle a higher volume, making it ideal for commercial use
Fibre lasers require far less maintenance and have longer service lives than other types of laser-cutting machines, meaning consistent results and little downtime
As they produce less wastage than C02 lasers and need less general maintenance, fibre lasers are more cost-effective
One of their key limitations compared to C02 lasers is that they can only be used for thin and medium-thickness metal sheeting, whereas C02 lasers can handle slightly thicker metals. However, this is rarely a limiting factor for projects.
If you’re searching for a metal fabrication partner in the UK, Salamander Fabrications can supply precision aluminium laser cutting in the UK for commercial clients. This means we can mass produce precisely cut aluminium products to large quantities and tight quality tolerances. We’re able to do this for several reasons:
We use two Bystronic fibre lasers in-house – one 3kw and one 6kw – running them 24/7 largely so we meet our clients’ large MOQs and keep to agreed timelines.
We can create a range of different high-volume products in a variety of sizes due to the 3000 x 15000 mm size bed of our flat bed lasers.
We maintain high-quality control with quality checks in our double ISO-accredited manufacturing facility.
We process at high speeds thanks to our automated laser and integrated handling system. Tight turnaround time is not a problem, just take a look at the large aluminium air distribution units we produced for a client in the construction industry. The first delivery was just 2 weeks from the order being placed.
If you have any questions or want to get in contact to explore our aluminium cutting services, please feel free to contact the Salamander team today. Drop us an email at sales@salamanderfabs.com or give us a call on 01484 843599.
FAQs about Laser Cutting for Aluminium:
What’s the thickness limit for laser cutting aluminium?
The maximum laser-cutting aluminium thickness will depend enormously on the softness and density of the metal as well as the wattage of the laser.
What wattage do you need for a fibre laser in order to cut aluminium?
Our lasers operate at 3kw and 6kw.
What exactly is laser cutting and what does it entail technically?
So, how do laser cutters work? In essence, laser cutting uses an intensely focused laser beam to cut materials such as sheet metals down to exact sizes and specifications. Other methods exist, such as CNC in which pre-programmed computer software controls machinery which in turn uses contact to carve out the pre-programmed design. Lasers are non-contact, meaning they use a beam of thermal heat to do the cutting.
How much does laser cutting aluminium cost?
This will all depend on factors such as the product being cut, the thickness of the aluminium, the quantity and the turnover. Speak to us today to discuss your needs, so we can provide you with a quote.
Many businesses involved in preparing food will rely heavily on food grade stainless steel. Using this type of metal, we at Salamander Fabrications make various equipment and instruments for our clients in the food and catering sectors.
So, what is food grade stainless steel? Essentially, it is a form of steel that is resistant to corrosion, wear and tear, and leaching in ways that make it ideal for food preparation. These are the properties that make it food-safe. There are several different types available that have slightly different formulations for unique catering purposes.
You can find out everything else you need to know by reading this guide, put together by trusted metalwork experts.
Food Grade Stainless Steel Explained
We regularly provide the food industry with sheet metal products. In the more than 50 years that we have been in business, we have extended our remit to supplying a broad range of sectors and businesses with items made from:
However, stainless steel is particularly often in demand among food businesses looking to fit out commercial and industrial kitchens with the likes of sinks, storage units and worktop surfaces.
This begs the question: what is food grade stainless steel specifically? Essentially, the term refers to any type of stainless steel known to be safe to use with food.
The rest of this easy-to-understand but comprehensive guide will explain the specifics of what it is and how it is used.
What Is It Used For?
The name itself refers to the various forms — or ‘grades’ — of stainless steel which subtly differ in their properties. Generally, though, it can be used for:
Cooking: This is because the metal is ‘non-leachable’, meaning that it won’t compromise how dishes taste.
Preparing food: As some foods — like curries and sauces — are extremely acidic, it is convenient that this metal is corrosion resistant.
Sustainability: Did you know that stainless steel is wholly recyclable? It’s also extremely durable compared to other synthetic materials. As a result, using it can help your business to meet environmental goals.
How Is It Made?
Stainless steel is an alloy made of numerous metals — including iron, chromium and nickel. These constituent metals are sourced from rocks.
For the consequent steel to count as stainless steel, it must contain more than 10.5% chromium. Generally, though, the chromium concentration has to exceed 14-18% for the stainless steel to reach a ‘food grade’.
Mother Nature handles the rest of the manufacturing process, as when the chromium reacts with air or water, a passive but protective chromium oxide layer will form on the stainless steel’s surface.
The Benefits: Why Use Food Grade Stainless Steel?
As we have previously alluded to, exactly what benefits you gain can very much depend on what specific grade the particular steel is. However, common plus points of this steel include:
Heat resistance: This is a prerequisite for stainless steel to be classed as ‘food grade’, and allows the metal to be safely used for handling hot food.
Long lifespan: Products can remain in good condition for some time due to being resistant to chipping and rusting.
Easily cleanable: Another appealing property is its smooth, non-porous surface, which makes it quick and easy to clean.
The Key Types of Food Grade Stainless Steel Available
By tweaking exactly how much of each element the metal contains, we can subtly modify its properties. This enables us to create sheet metal products tailored to suit specific applications.
This particular food safe metal is available in a wide range of grades each represented by a three-digit number. Though most of these stainless steels come in grades starting with a 3 or 4, the key grades are as follows:
SS316
This grade of stainless steel is chosen for many different products — like containers, sinks and pipes — that come into contact with food.
With its chromium content of 18% and nickel content surpassing 10%, this austenitic stainless steel is highly rust resistant. It is also chemically resistant to salt as well as strongly acidic foods, e.g. lemon and tomato juice.
Like other stainless steel alloys, SS316 can withstand temperatures much higher than what would usually be required at many stages of food processing.
SS304
The vast majority of companies in the food processing industry are likely to be able to benefit from the renowned affordability of 304-grade stainless steel.
This corrosion-resistant metal can hold up well when exposed to numerous oxidising agents — allowing it to be sanitised with ease. Many of your workers could come to especially appreciate this when working packed shifts.
Also, you can trust us with welding SS304 sheet metal particularly effectively — making it a great choice for such products as dishwashers and storage tanks.
SS430
Though SS430 food grade stainless steel has the same amount of chromium as the SS316 alternative, the former has far less nickel. This all means that SS430 is the most cost-effective option of the lot.
This — along with its impressive resistance to organic and nitric acids — often makes SS430 the go-to material in situations where the product is expected to long remain in contact with compounds containing such acids.
It would also be worthwhile for you to consider SS430 if you are particularly concerned about the risk of corrosion cracking.
Salamander Fabrications Provide Superior Quality Metals for the Food Industry
One major reason why is that we can manufacture and provide food safe metal items not only in the quantities your business needs but also to commercial timelines.
Our Precision Equipment
We are able to handle your metal fabrication project entirely in-house at our Huddersfield premises.
This is largely due to the specialist equipment we maintain and use onsite. We also regularly assess and update this machinery to keep pace with new developments in metal fabrication technology.
A Team of Metal Fabrication Experts
Here are just some of the reasons why our team can fabricate high-quality metal products for your business:
Are you familiar with many types of laser cutting? Do you know which of them would best serve your business?
If you’re searching for the best laser cutting methods available for your business, we have all of the answers you need right here. If you’re also searching for an expert metal fabrication service that can fulfil those needs, you can take advantage of our many years of expertise in custom laser cutting services.
We are Salamander Fabrications, a Yorkshire-based team of experts in metal fabrication. Today, many businesses that need metal fabrication services choose to place their faith in us. If that sounds like you, get in touch.
Having built up an array of impressive credentials in our line of work, we’re confident in providing you with a comprehensive guide to the different kinds of laser cutting available.
Understand The Key Types Of Laser Cutting
The two types of laser cutting you are likely to hear about most often are CO2 cutting and fibre cutting. Our custom laser cutting service uses fibre cutting.
This is because we ultimately deem it more effective than many alternative approaches to laser cutting — including crystal and direct-diode techniques.
In this article, you will be able to easily pick up comprehensive details about:
Different types of lasers used for cutting
These lasers’ use cases, strengths and weaknesses
Essentially, laser cutting works by focusing a laser beam on a given material, in the process reshaping or distorting it with heat and pressure. If you want a deeper understanding of exactly how we achieve this, get up to speed with our answers to the question ‘what is laser cutting’ before you read on.
Co2 Lasers
These are sometimes referred to as gas lasers, as they produce light beams by running a mixture of gases — including carbon dioxide, but also potentially nitrogen, helium and hydrogen — through a tube.
This type of laser is most often used on relatively thin materials like paper (e.g. wallpaper), fabric, leather and wood.
Though CO2 lasers do not tend to be applied to metals, they remain generally capable of piercing thin sheets of non-ferrous metal, such as aluminium.
Benefits
Can cut a wide range of thin materials
Also useful for processing food like cheese and chestnuts
Can cut through various thicknesses at the same (or lower) power
Do not leave irregularities in material cuts
Also suitable for boring and engraving
Impressive energy efficiency
High power output ratio
Cost-effective
Some CO2 lasers can deliver multiple kilowatts of power
More oxygen can be added to the CO2 beam to strengthen it
Weaknesses
Not suitable for cutting thick metal sheets
Using it to cut metal might lead it to spark or catch fire
Metal cutting jobs can damage the mirrors attached to the tube
Typically limited to 25 to 100 watts of power
Adding more oxygen to the CO2 beam can be risky
This oxygen can potentially catch fire
Fibre Lasers
We use fibre lasers as standard for a wide range of sheet metal fabrication jobs. Fibre lasers are so-called as they work using optical fibre and operate by sending the laser beam through fibreglass diodes, which also amplify it.
Fibre lasers deliver a lot of power for the electricity expended. These lasers can also cut both metallic and non-metallic materials – for example, plastic, glass and wood.
A fibre laser is also the best type of laser for cutting reflective materials, as there is no danger of the laser being reflected off the material.
Benefits
Capable of delivering consistently strong beams
Can achieve extremely precise results compared to CO2 cutters
Can cut more smoothly, quickly and flexibly than CO2 cutters
Much more energy efficient than CO2 cutters
Produce less waste than CO2 cutters
Do not require any flow of gas
Generally do not entail any maintenance
Have a far longer service life than CO2 and crystal lasers
Weaknesses
Usually the most expensive laser cutting machines
Some fibre laser cutters can struggle to effectively cut materials thicker than 20mm
Many fibre laser cutters come with various settings potentially confusing to people inexperienced at laser cutting
Crystal Lasers
Crystal laser cutters can be sorted into the following two broad categories:
Neodymium-doped yttrium aluminium garnet (Nd:YAG)
Neodymium-doped yttrium ortho-vanadate (Nd:YVO)
Each of these terms refers to a specific type of crystal used by the laser machinery — with Nd:YVO crystals being used more often.
Nd:YAG and Nd:YVO units can be compared across a range of measures. For example, while Nd:YVO lasers are broader in bandwidth and higher in thermal conductivity, Nd:YAG lasers last longer and allow for higher pulse energies.
Crystal lasers are used in numerous sectors — including manufacturing and the medical industry.
Benefits
Can cut through relatively thick and tough materials
Offer extremely high cutting power
Can operate continuously
Nd:YVO and Nd:YAG cutters often perform similarly to each other
Also good at cutting a number of non-metals, e.g. plastics
Can cut a few ceramics (albeit only in particular circumstances)
Weaknesses
Can be costlier to buy than other laser cutting machines
Have a low expected service life of 8,000 to 15,000 hours
Rely on pump diodes that can be expensive to replace
Can be less serviceable than alternative laser cutters
Nd:YVO lasers can only run continuously when on medium or high power
Direct Diode Lasers
Here’s a simple question: how does a laser work? Basically, it starts working by using an electrical discharge to stimulate what is referred to as a ‘lasing material’.
All the while, this lasing material is kept in an enclosed container. It is not until after the lasing material is stimulated that the laser cutting machine creates the laser beam — and uses optics to direct it onto the workpiece material.
A direct diode laser is a type of solid-state laser, as its lasing material is in solid form, rather than, say, gas or liquid form. A glass rod in a direct diode laser is doped to bring about the laser action.
Benefits
Uses familiar (and so tried-and-trusted) laser cutting technology
Already mainly used for cutting metal
Some direct diode lasers can tap into multiple kilowatts of power
Produce poorer laser beams in comparison to fibre lasers
Are usually not as powerful as other models of laser cutting machine
Typically only deliver about 10 watts of power
How Do You Choose the Right Type of Laser for Your Project?
Contrary to popular belief, laser cutting is not a ‘new’ technology, as its genesis can be traced back to roughly the 1960s.
However, as many different types of laser cutting machine have since been built, you could struggle to select the right one for your metal fabrication project.
Below, we compare the properties and advantages of various laser types to assist you in matching the right laser cutter to your specific metalworking job.
Cutting vs Engraving
Laser cutters are mainly used for either cutting or engraving. So, before choosing a laser cutter, decide which of these two processes you need.
Another factor is how the material will react to the process. If you seek engraving, for example, you should go with a cutter built for the required precision.
Performance
While somewhat low-power equipment might suffice for laser cutting on a hobbyist level, what if you need to have metal cut for manufacturing purposes? In that case, you might require a cutter high in penetrative power.
However, a bigger factor in a laser cutter’s performance is its optics. So, pay more attention to a cutter’s optics than its power consumption.
Bed size
How much metal cutting or engraving work needs doing, and for what deadline? Your answers will very much determine what size of bed you should choose for the laser cutter.
It’s a simple equation: the larger this bed, the larger the amount of work the cutter will be able to complete at a time. So, for metalwork jobs that need to be finished both quickly and in high quantities, a laser cutter with a large bed would fit the bill.
What materials can laser cutting be used for?
As laser cutters can pierce any kind of metal, they serve crucial purposes here at Salamander Fabrications. These metals can be used on metals including:
Can lasers also cut plastics? Yes, some plastics — but others can be dangerous to cut in this way, e.g. due to gases they would release.
Salamander Fabrications’ Precision Lasers
By investing heavily in our equipment and staff training, we can steer laser cutting projects to success every time. This dedication means that clients can always look forward to seeing great results in line with the brief.
Here are a few examples of what we do to safeguard our high standards:
We’ve got lasers that cut twice as quickly as the average – We’ve implemented an automated laser and integrated handling system engineered to cut sheet metal twice as quickly as our existing machines.
We’re always investing in our specialist machinery – One major incentive to task our team with laser cutting on your business’s behalf is that we have acquired equipment enabling us to handle such jobs with efficiency.
Has your curiosity been piqued by CNC punching? Perhaps you have only recently heard of this metal fabrication process for the first time, and want to understand it better.
Alternatively, you might have heard about CNC punching before but are unsure what its practical applications and advantages are for your business. We explore all of that here.
Since starting out in Huddersfield more than five decades ago, we have established Salamander Fabrications as sheet metal fabrication experts — and one of the UK’s most trusted choices for welding.
Our services also include powder coating and electro mechanical assembly. As a trusted source of information on metal fabrication, we have prepared the following guide to everything you need to know about CNC punching.
What Exactly Is CNC Punching?
CNC punching is essentially a sheet metal manufacturing process undertaken with the use of CNC punch presses. These CNC machines can be sorted into the following two broad categories, depending on the unit’s design:
Single head and tool rail
Multi-tool turret
The ‘CNC’ stands for ‘computer numerically controlled’. This refers to how software is used for programming the punch press to appropriately position a metal sheet in preparation for punching a hole or form into it.
In tailoring how you set up the machine, you can enable it to punch shapes of your choosing and so help you create simple or complex sheet metal parts.
Benefits of CNC Punching
With a CNC punching machine, designs and any materials you need to produce the parts you require, you can harness the following benefits:
A high level of customisation: In programming the machine, you can ensure it uses precise coordinates to punch the specific shape you need.
Time efficiency: The above coordinates can constitute a ‘template’ for use in speedily producing multiple copies of the same piece.
The ability to create pieces in many different forms: These include beads, louvres and countersinks — none of which a laser cutter could produce.
Reduced waste: The precision with which a CNC machine cuts out shapes means that more of them can be fashioned from a single sheet.
CNC Punching Glossary to Get You Started
As you get started with CNC Punching you’ll notice that there is a lot of specialist language to take on board. For this reason, we’ve put together an easily digestible glossary of terms used around CNC punching.
CNC Punch Press
A specialist type of electromechanical device that securely holds a sheet of material while punching holes or forms into it. The desired design is programmed into the machine beforehand.
CNC Program
A digital set of instructions fed into a CNC machine to direct it to construct a component of the required design. The CNC program can be provided in either a 2D (DXF or DWG) or 3D (Computer-Aided Design, or CAD) file format.
Cluster Tool
A tool that can be affixed to a CNC machine to enable it to punch many more holes in one go. A cluster tool can come with multiple separate punches allowing thousands of holes to be punched each minute.
CNC Engraving
Engraving carried out with a CNC punch press. The engraving design can be programmed into the machine beforehand. This allows — for example — names and numbers to be engraved on individual products and components.
Types of CNC Punches
There are many different types of CNC punch press, and which of them you ought to use will depend on the demands of the project at hand.
Here is a short guide to some of the most popular CNC punches you may encounter and their intended purposes:
Single Head Punching Machines
You might have often seen these described as having a ‘single head and tool rail’ design.
With these CNC punch presses, just one tool is inserted into the punching head at a time. Meaning that the tool can be fully rotated while in place.
Multi-Head Punching Machines
Otherwise referred to as ‘multi-tool’ or ‘mould’ CNC machines, these hold multiple tools simultaneously, with each one kept in a set position in a circular turret.
As this type of CNC punch press is capable of holding three to four rotational tools, along with dozens of additional tools, you would be able to quickly produce large numbers of holes and forms in a wide range of shapes.
Hydraulic Punch Heads
A hydraulic CNC punch press functions by using a pump to run liquid through a hydraulic pipeline and into the machine’s cylinder or piston. The hydraulic system regulates the degree of pressure exerted on the cutting tools.
Complex Contour Tool Rail Systems
CNC punch presses can be relied upon for contour cutting where intricate shapes are cut out of materials including foam and rubber.
Perfect CNC Turrets for Complex and Rotation Axis Tasks
CNC machines in this category can combine a hydraulic punching head with a rotation axis for any tools you wish to secure to the punch press.
Materials Suitable for CNC Punching
CNC punching is an ideal sheet metal manufacturing process for thin sheet metals, as well as other materials of similar thickness. As a CNC punch press can typically machine thicknesses from 0.5mm to 6mm, any material in this range can usually be CNC punched.
That leaves you with many different options when it comes to compatible materials. Naturally, though, these will still vary in their strengths and weaknesses and, as a result, which applications they can be best used for.
Here are several examples of materials you could consider incorporating into CNC creations, such as for different types of health and safety careers.
Stainless Steel
With its impressive strength, corrosion resistance and ease of maintenance, stainless steel is often used in medical settings. For instance, as for handrails and wheelchairs.
It is also used for sterilisable surgical instruments, as it will not corrode in extreme temperatures.
Aluminium Alloys
One such example is aluminised steel, which combines aluminium with carbon steel. This provides the former’s corrosion resistance and the latter’s high strength in one single alloy.
Aluminised steel has long been used for manufacturing kitchen appliances, due to their need to withstand high temperatures.
Brass and Copper Alloys
Brass combines copper and zinc — and those constituent parts’ proportions can be altered to affect the overall alloy’s exact properties.
This helps to explain the sheer versatility of brass — which, being softer than many other materials, is also easier than them to puncture.
Other Metals and Alloys
Titanium has a high strength-to-weight ratio and is often chosen for the production of construction elements.
CNC punching may also be used on high-strength steel that, comprising steel and other elements like copper, carbon and manganese, is well-suited to military armour plates.
LED Panels
LED panels can — due to their perforated features — be made especially quickly with CNC machines using cluster tools that punch multiple grid holes simultaneously.
Planning a Metal Fabrication Project? Salamander Fabrications Can Help
We have honed our expertise in many different metal fabrication techniques — including custom laser cutting and metal folding — for clients from various sectors, among them retail, leisure, transportation and the food industry.
Salamander Fabrications are able to professionally complete a wide range of sheet metal work for your UK company’s benefit. Our metal fabrication services are available to commercial clients nationwide.
Why Clients Choose Us
Over the years and decades, we have been able to continually grow our company on the back of customer service delivered to a consistently high standard. Here are several reasons why clients keep turning to Salamander Fabrications:
We’ve got a reputation in the industry: Our dedication to getting everything right the first time when working with clients has led many to spread the word about us. We are very grateful for how client testimonials have fuelled our success.
Big and small businesses depend on us: We work with companies from a variety of sectors (enabling us to help with, for example, many different types of health and safety careers) as well as their sizes.
Reliable results: Through handling all of our metal fabrication assignments in-house and approaching trusted partners when we need to tap into their specialist expertise, we have succeeded in hitting targets again and again.
To learn more about the work we do or to get started with your next project, please don’t hesitate to get in touch with our friendly sales team on 01484 843599 or at sales@salamanderfabs.com.
FAQs: Your CNC Punching Questions Answered
In case you have any lingering queries about how CNC punching works, we’ve answered some of the most popular queries regarding CNC punching below.
How does CNC programming work?
CNC programming involves developing digital instructions that a CNC machine would be able to read in order to manufacture a specific part.
A CNC programmer will construct a sequence of instructions on how the machinery should operate in order to make a specific item, usually based on studying a paper or digital model.
What can CNC punching create?
CNC punching can aid you in carrying out a vast range of metal work. This means that CNC punching can prove useful for various sectors — among them aerospace, architecture and construction.
The useful features that CNC punching can create both time- and cost-effectively include:
Louvres
Dimples
Grilles
LED panels
Is CNC punching right for my fabrication needs?
For many people, CNC punching is appealing due to its ability to produce products and parts in geometrically precise shapes without inflicting spatter or scratches.
However, whether CNC punching would be suitable for your own requirements will strongly depend on what you are looking to achieve and to what budget and timeframe.
Does CNC punching require bespoke machinery?
Exactly how ‘bespoke’ a CNC machine needs to be will depend on the design complexity of the product or part you are eager to make.
For example, a CNC machine can create not only simple rectangular or circular holes but also cutouts in custom patterns.
In order to cut to bespoke designs, you can suitably program the CNC punch press as well as attach physical add-ons — e.g. cluster tools — to it.
In this comprehensive guide, we’ll start by defining: ‘what is metal stamping?’ before explaining exactly why you might consider it as a metal manufacturing process. Metal stamping is a specific process that involves transforming sheet metal into various shapes. We at Salamander Fabrications are metal fabrication specialists, so we’re well-placed in the industry to guide you on what metal stamping entails.
The following guide will explore the answers to the following questions:
What is metal stamping in sheet metal?
What does the metal stamping process involve?
What are the different types of stamping techniques?
Where is metal stamping applied?
At Salamander Fabrications, we are the leading experts in metal sheet fabrication in the UK, meaning that you can count on us for your metal fabrication needs – regardless of the size of your requirements.
Without further delay, let’s begin our informative deep dive covering ‘what is metal stamping.’
What Is Metal Stamping & What Are Its Use Cases?
As touched on already, metal stamping transforms sheets of metal into specific shapes, of which the finished product is often a useful component that could be used in a number of applications (more on this later). A high volume of metal parts can be produced through metal stamping, making it a highly important process as demand grows.
The Definition of Metal Stamping
Sometimes referred to as ‘metal pressing’, metal stamping is a complex manufacturing process that creates shapes from sheets of metal. This is done through a cold-forming method that forms the desired shape via a stamping tool, also known as a die. The die presses into the metal sheet with intense force in order to create the shape.
An Overview of the Metal Stamping Process
Here is a simple, step-by-step explanation of the preparation for sheet metal stamping:
Computer-aided design (CAD) and computer-aided manufacturing (CAM) are used to design the tooling for the stamping process. These designs are accurate and precise to ensure that there is adequate clearance for each cut or bend, consequently producing high-quality metal parts.
Raw materials (sheets of metal) are acquired.
Tooling machines for the dies can be used to accommodate specific stamping needs.
The stamping machine itself can be programmed or computer numerically controlled (CNC) to ensure high precision.
Once set-up is complete, the actual stamping begins:
The flat metal sheet is inserted into the stamping machine.
A tool and die form the desired shape into the metal through a specific technique (such as blanking, piercing, punching, or bending.)
The finished product may then be further processed or treated.
Tool Setup and Preparation
The metal stamping process involves the use of machines and the die – both of which can be tailored to match the requirements of the stamping project. Each metal stamping press can have a variety of features that are designed for exact stamping demands.
Stamping Press Operation
During the process, the stamping press will usually be inspected to make sure that it is performing as it should. Various stamping methods can be used. These include:
Blanking – sheet is fed into the press where the die cuts out the shape
Forming – tremendous force is applied to transform flat metal sheets into another shape
And more…
The method used can affect the pressure and speed that the stamping press will apply.
Post-Stamping Procedures
After stamping, the metal parts might undergo further treatments to perfect their appearance. This includes deburring, smoothing out any rough or sharp edges, and cleaning minor imperfections. Some parts might also be further coated to improve their appearance and/or performance.
As you can see, metal stamping is a versatile process that offers a myriad of different possibilities and approaches.
Metal Stamping Techniques & Types
There are a variety of metal stamping techniques to be aware of. A few examples are:
Progressive Stamping
Progressive stamping involves the metal sheet being fed into the stamping press, and then passing through multiple stations with unique functions. These are often metalworking processes like punching, bending, or cutting. It will stop at each station, continuing the work of the previous station for a complex shape.
This means that progressive die stamping is frequently used for:
Beverage can lids
Electronic components
Appliances
Automotive parts
Transfer Stamping
Transfer die stamping is another type of metal stamping that is similar to progressive stamping, with several differences. With transfer stamping, the workpiece is separated from the metal strip and a mechanical transport system moves it from station to station. This is ideal for producing large metal workpieces that cannot easily move from one die station to another.
The following industries benefit from transfer die stamping:
Agriculture
Automotive
Medical
Electronics
Single Station Stamping
As its name suggests, single station stamping refers to a stamping technique that only utilises one station. It offers a straightforward process for producing metal parts, but also requires dies to be replaced if performing a new operation.
As single station stamping can only handle one operation at a time, they are best suited for basic metalworking jobs like:
Blanking
Piercing
Drawing
Which Metals Can Be Used in Metal Stamping?
Metal stamping can be used on a range of metals, such as:
Steel alloys – including stainless and low- and high-carbon
Titanium
Choosing the Right Metal
It is worth mentioning that material selection can impact the final product. Each metal has different properties that affect how it progresses through the stamping process.
For instance, copper alloys are often used for medical and food processing applications due to their antimicrobial properties. Aluminium on the other hand might be used for lightweight electrical components as it is an excellent electrical conductor.
Material thickness also plays an important role in the quality, functionality, and durability of the metal parts, which is why considering the thickness of the material is essential.
What Is Metal Stamping Uniquely Useful For? The Benefits
Now that you have a comprehensive answer to, ‘What is metal stamping?’, you might be wondering how you can benefit from this process. In particular, precision metal stamping offers the following advantages:
Precision and Accuracy
CNC stamping machines offer exact precision and accuracy when it comes to forming metal parts. As a result, even small metal parts can be manufactured, and made completely identical to one another.
High Production Rates
Metal parts can be produced at an exponential rate, enabling high volumes of products to be formed quickly. This is because the stamping press can process multiple parts at once, shortening production time significantly.
Cost-effectiveness
In comparison to other stamping processes, the costs of metal stamping are relatively low, making it a cost-effective solution for creating various metal parts. Production and maintenance costs are also generally cheaper, which is a great benefit that you could reap in terms of reducing overhead costs. As the process is highly automated, labour costs can be reduced as well.
Consistency in Quality
Using CAD/CAM designs and automated controls and tooling, you can expect consistent products that are always of high quality. The repeatability of metal stamping guarantees accurate dimensions every time. Each component is identical to a fractional degree of accuracy.
Minimal Material Waste
Precision metal stamping means that minimal waste is produced during the process – the minimum amount of material is used, ensuring that most, if not all, of the material is efficiently stamped, leaving the littlest scraps behind.
Which Industries Have Applications for Metal Stamping?
Numerous sectors in the metal sheet fabrication industry can benefit by taking advantage of metal stamping. The following sectors have applications for stamping sheet metal:
Automotive Industry
Metal stamping is crucial for the automotive industry, particularly as many components and parts are manufactured through this process. Examples of components produced through metal stamping are:
Brackets
Frames
Fuse clips
Bars
Fasteners
And more…
There are many safety and quality standards to take into account regarding the manufacturing of parts for the automotive sector. Ensure that your supplier adheres to rigorous processes to ensure that they only produce high-quality and safe products.
Electronics and Appliances
Electronics and appliances, including kiosks, vending, and enclosures are also a sector that we work in that could also benefit from metal stamping. Stamped products from this sector include:
Covers
Fasteners
Clips
Components for a range of appliances, including microwaves, refrigerators, grills, and more
And more…
High-quality stamped products are key to product functionality, especially as some components will need to be of a specific size and shape for installation purposes.
Aerospace and Aviation
The aerospace and aviation industry require complex components that are manufactured through metal stamping, such as:
Air restrictors
Landing gear
Internal systems
Plates
Fixtures
And more…
Stringent requirements and regulations are in place within this industry, so you can expect the strictest quality control measures to ensure that the final products meet these standards.
Consumer Goods and Packaging
The retail and leisure sector, which also involves consumer goods and packaging, is another industry that we work in. Consumer products are also created and packaged through the sheet metal stamping process. This includes:
Product packaging – skincare and beauty products
Batteries
Food and beverage cans
Furniture hardware
And more…
Utilising precision metal stamping for consumer goods and packaging can help contribute to a greener society, especially when it comes to minimising waste materials.
Look for Precise Quality Control in Metal Stamping
Metal stamping services utilise modern technology and specialist skills to produce large volumes of metal parts for numerous industries.
Quality Control
Quality is of the utmost importance when it comes to the stamping process, especially as every cut, curve, and edge of the metal will need to be precise and accurate. This is why at every stage of the metal stamping process, quality control measures should be conducted to ensure that your provider maintains the highest standards of product control.
Equipment Inspections
Your metal stamping provider should undertake regular inspections of equipment, including press brakes and other tooling, to make sure they are not only safe to use, but maximise their efficiency and performance.
Compliance and Certifications
Look for certifications to back up your metal stamping specialist’s credentials. They should be keeping on top of industry standards. ISO 9001 certification is one way to see whether a metal stamping company is serious about quality management.
Metal Stamping: Commitment to Sustainable Metal Manufacture Processes
In general, metal stamping is considered to be an environmentally friendly metal manufacturing process, particularly as metal is a sustainable material that can be used and reused multiple times. As a process, metal stamping relies on precision which means minimal waste. However, this does not mean that the stamping process has zero impact on the environment.
Look for ISO 14001 certification from your metal stamping specialist. This showcases commitment to environmentally friendly practices.
Green Practices
At our facilities, we have implemented green initiatives to prevent excessive waste. This plan incorporates responsible recycling and disposal practices, as well as utilising energy-efficient machinery and equipment.
We take care to ensure that only a minimal amount of waste is produced during metal fabrication, and if there is waste, then we manage and dispose of it appropriately. At Salamander, we encourage a workplace environment that fosters sustainability. We’re also ISO 14001 certified.
Looking for a Partner Who Provides High Quality Industrial Metal Fabrication? Choose Salamander Fabrications
Salamander Fabrications was established in 1968, and has been providing exceptional metal stamping services for commercial operations across the UK ever since. With 50 years of industry experience and expertise under our belt, you can rest assured that we are a reliable metal fabrication company that is committed to delivering beyond your expectations.
When it comes to metal fabrication, we can effectively transform sheets of metal into whatever metal parts you require. With excellent lead time and first-rate quality, we are the full-service metal fabrication company to turn to.
CAD is an essential technique used in our bespoke metal fabrication process here at Salamander Fabrications.
CAD allows for careful planning of a wide range of requests or concepts you may have, providing a visual construction of your finished product before we start production! Perfect for your sheet metal projects to be brought to life with our expert CAD technology!
Since you’re here, you may be wondering “how is CAD used in bespoke metal fabrication?” Prepare to have your questions answered as we’re here to solve all your queries!
Get in touch with our expert team today if you’d like to know more about how we use CAD in our fabrication process to give you the best quality from our sheet metals- we’d love to hear from you!
What is CAD?
CAD stands for computer aided design, and for us is often the first stage of the fabrication process. CAD technology maps out a plan for what we need to build and how to get your sheet metals to that stage. Any of your bespoke metalwork can be planned, modelled and viewed with either 2D or 3D technology.
As well as being an effective method of design, CAD ensures precision for your fabrication needs and allows us to deliver the same quality service our team are known for.
CAD is integral in providing a visual picture of your bespoke metal fabrication as the computer software creates a 2D or 3D image that maps out the shape and dimensions of whatever metal sheet products you desire. This advanced technology can turn your idea into a reality!
Our expert CAD designers ensure you have quality products with a top-notch appearance and careful planning behind them, not to mention the added bonus of cost-effectiveness that CAD can add to your projects.
What Is Sheet Metal Fabrication?
Sheet metal fabrication is the process that transforms raw metal sheets into your desired shape and design. Our extensive specialist skill-set means we can execute your bespoke metal designs to the highest quality- whatever you need, we can create it!
Adapting our models to create entirely new and bespoke designs for our customers is at the heart of what we do, and CAD technology is a tool that we can use to effectively turn your concepts into concrete designs.
Bespoke metal fabrication means we can create a wide range of products that fit whatever you’re looking for, combining and shaping separate metal components to form the end product. The possibilities are endless with sheet metal fabrication, allowing for any unique and custom-made designs.
How CAD Is Used For Bespoke Metal Fabrication
In addition to creating 3D designs product visualisations, CAD can also be used to move projects from design into fabrication. Instead of having to manually convert the design, CAD technology automatically creates a plan that manufacturing tools and CNC machines can read and then execute. It truly is the gift that keeps on giving!
A range of different computer programmes are used so that your bespoke designs can be made as accurately, effectively and quickly as possible. Not only does CAD include graphics of the desired objects, but also the technical information necessary to nail the precision of your bespoke products.
One of the key reasons that CAD is essential for bespoke metal fabrications is its ability to create increasingly precise designs. Nothing is off the table for CAD design!
We work closely with our clients to ensure a design is created based on their wants and needs. Products that are fit for purpose are guaranteed with our CAD technology, and bespoke designs have never been easier to obtain.
FAQ’s
What are the 3 types of metal fabrication?
The three main types of metal fabrication are considered to be cutting, welding and assembling. Our processes also include custom laser cutting, press bakes / metal folding and finally electro mechanical assembly to achieve an outstanding final product.
Is metal fabrication in demand?
Currently, metal fabrication continues to be in high demand as clients seek out bespoke metal fabrications. The advancements in technology that make the fabrication processes efficient and cost-effective have allowed for a wider range of possibilities that can meet your unique requirements and specific design ideas.
What is the future of metal fabrication?
There is certainly a bright future ahead for metal fabrication! The industry is expected to grow into 2024- new trends of 2023 have already propelled it forwards, and the unstoppable advances in technology are opening up many new doors for metal fabrication possibilities.
Various sectors that have continuous demand for metal fabrication indicate a secure and developing future. In fact, the metal fabrication market size is expected to reach a value of $473.7 billion by the end of 2031!
Choosing Us For Your Bespoke Metal Fabrication
Choosing Salamander Fabrications for your bespoke metal fabrication guarantees you high-quality, cost-efficient products with exceptional customer service at the very forefront of our business! Choosing us means choosing intelligent, up to date CAD technology that delivers precision for whatever design you have in mind.
Contact us by phone at 01484 843599 or email sales@salamanderfabs.com. You can even browse our recent projects to see first-hand what our processes can produce.
Welding has been used for hundreds of years as a way of joining two pieces of metal together. In the past, this was done through forge welding, but now there are other ways such as flame, electric arc, laser, electron beam and friction.
Regardless of the technique used, welding can be a hazardous job, and this is where health and safety in welding is so important. There are many risks associated with welding, not just from the task itself, but also from other issues such as welding fumes that produce toxic gases and damage to the eyes and lungs. Because of these risks, there is legislation in place to protect workers and ensure injuries are minimised.
Which Legislation Affects Health and Safety in Welding?
In the UK, there is legislation that looks to protect workers from the dangers of welding. The main problem is the inhalation of hazardous substances which can lead to health conditions such as lung cancer and asthma.
The main piece of legislation is COSHH (Control of Substances Hazardous to Health). This requires employers to protect their workers who are tasked with welding. Part of this is to provide adequate ventilation so that any exposure to welding fumes is kept to a minimum.
Employers are also required to provide adequate PPE (Personal Protective Equipment) so that risks to health through injuries are also minimised.
Another piece of legislation that covers welding is the Health and Safety at Work Act. This together with COSHH ensures that employers are taking care of their workers and reducing the risk of exposure to dangerous substances and other health effects.
Important Health and Safety Considerations in Welding
Both the Health and Safety at Work Act and COSHH are created to help workers get the protection they need, as well as giving employers the guidance they need to keep welders safe. There are many elements to this that go beyond fuel gases, exposure to fumes, and dust. There are also other adverse health effects that welders can be exposed to.
It is also important to ensure that a general level of safety is maintained so that workers and others around the working area are protected.
Creating a Safe Workshop Environment
Part of working in workshops is that you are going to be exposed to dangerous activities on a daily basis. Having effective control measures in place gives everyone the ability to protect themselves and others. It also provides a base level of safety that everyone must meet.
The workshop and workstations must be kept tidy and any electrical welding equipment not being used needs to be switched off. Each area where welding is performed must have adequate exhaust ventilation systems to protect from harmful levels of toxic fumes.
Managers are required to ensure the hierarchy of control measures is being adhered to and appropriate procedures are being followed.
Maintaining a safe place of work begins with adequate training and reinforcement of safety guidance. Any new procedures or safety legislation must be put in place and staff trained on the new guidance.
Electrical Safety
When performing electric arc welding, there is a great risk of electric shock. This can cause serious harm if the right procedures are not put in place. Welding cables need to be secure and used in the correct manner. Electrical welding equipment must also be used safely and inspected regularly for any damage or repairs that may be needed.
These preventative measures ensure that the welding process is as safe as possible and any risk is minimised.
Make sure all cables are in good condition and have no bare insulation or frayed wires.
Protect wires and cables from damage from vehicles and other hazards.
Ensure that the rod holder is insulated correctly.
When replacing the welding electrode, do not do this with bare hands or a wet welding glove.
You must always keep your hands and body dry when welding.
Avoid all contact with live parts of the welding equipment and the workpiece during the welding process.
Always have the welding transformer in close proximity. This ensures that it can be easily switched off in the event of an accident.
Do not hold or move the welding electrode together with the return cable at the same time when moving from one working position to another.
Fumes
In 2018, the IARC (International Agency for Research on Cancer) classified fumes from welding as a Group 1 carcinogen. They found that there was sufficient evidence that humans who inhaled carcinogenic materials from welding had a higher risk of getting lung cancer. There was also the potential to cause kidney cancer.
Exposure to the fumes created from welding has been found to potentially cause a range of health conditions. For example, mild steel welding fumes have been linked to neurological symptoms similar to Parkinson’s disease.
Together with these conditions, there is also a range of respiratory conditions that are also linked including:
Metal fume fever
Chronic Obstructive Pulmonary Disease (COPD)
Asthma
Increased susceptibility to pneumonia
Employers need to consider whether the current control measures are sufficient to reduce the risk, looking at the way flammable gases and inert gases are being removed from the work area adequately. This means the following need to be assessed:
The welding process and the volume of work against the amount of fume generated
The size of the component being welded
The position of the piece that is being welded
What type of metal is being welded (mild steel, stainless steel)
Whether the welding is being done indoors, outdoors, or in a confined space
Consider whether the clearance for ventilation is adequate
Noise and Noise Cancelling Provisions
When it comes to noise, this is generally associated with heavy fabrication. This includes the fabrication of larger-scale metal products, chemical manufacture, pressure vessels, storage silos and structural steelwork.
Considerations need to be made towards the approach to reduce the levels of noise and how that can be achieved. Some tools create more noise than others, and it may be impossible to avoid using them. If this is the case, then the amount of time using them should be limited if possible.
Another option is to use enclosures to limit the noise and the use of permits to use those tools that are the loudest. Once the measures have been put in place, there needs to be constant assessment during welding activities to see if additional measures are required such as ear protectors.
Together with assessments for those working with noisy tools and equipment, there also needs to be a consideration for those around them. Noise pollution may create problems for other workers in the vicinity of the noise. Measurements of the noise levels in the area will determine whether additional safety measures will be needed.
Eye Protection and Safety
Eye injuries caused by welding are common. This is often because welders don’t wear the appropriate PPE such as safety goggles or face shields. This is an area that needs to be enforced as there can be a low perception of risk from some workers.
Wearing a welding helmet isn’t enough protection. Along with the helmet, workers also need to wear safety goggles or safety glasses. Goggles will provide better protection from activities such as gas welding.
The biggest issues that result in injuries to the eyes include:
Mechanical damage from being struck by flying particles and other debris including molten metal particles
Radiation damage and photochemical burns from ultraviolet radiation, infrared radiation and intense blue light
Irritation to the eyes from chemical fumes
Some injuries can occur quickly, while others such as radiation exposure can affect the eyes over time. One such condition is arc eye or arc flash. This is a painful condition that causes swelling, tearing and pain. This injury isn’t usually permanent, but continued exposure could cause additional problems.
Correct safety training along with health surveillance and monitoring will help to reduce the risk of injury to the eyes. Safety in welding information also needs to be on hand at all times so that workers have access to it.
To create an effective overall eye protection plan when welding, you need to consider these things:
Review the area where welding will take place and put safety measures in place
Ensure the area around the welding area is free from trip hazards. Welders who are wearing goggles and masks cannot see around them easily
If other staff are working in the area, consider fitting curtains to absorb the radiation
Cover any highly reflective surfaces to protect from glare
Always wear the appropriate headgear and goggles depending on the type of welding being undertaken
If other workers are also in the area, they may also need to wear eye protection
Gloves and clothing that protect from UV radiation should always be worn when welding
If anyone receives a flash burn injury then they need to seek medical attention immediately to prevent a permanent injury
Training is essential when hiring and working with welders. This training must be kept up to date with new regulations and safety procedures
Mechanical Hazards and Burn Risks
Mechanical hazards and burn risks are also a regular occurrence for welders if they don’t follow the correct procedures. One of the most serious issues is burns, which can happen quickly and be potentially serious if not treated.
The combination of high-temperature welding arcs, UV rays and drips of metal can make welders susceptible to burns. Most of the instances of burns from welding are where the welder thinks they can skip the safety procedures for a quick piece of welding. However, this is considered bad practice and should be forbidden in the workplace.
Mechanical injuries can manifest in the form of musculoskeletal injuries from a piece of metal that has fallen or not been secured properly. Other injuries can occur from combustible substances that ignite during the welding process.
Any injury that occurs in the workplace should be reported immediately. Medical help should be sought and first aid administered by a trained colleague. After the accident, a complete safety inspection should be carried out to ascertain what caused the injury and if any additional safety procedures are needed.
Welding in Difficult Situations
When welding in situations that are not the usual areas such as in confined spaces and outdoors, then special measures should be put into place to protect the welder.
Toxic gases can be hazardous, especially in a confined space. Respiratory irritation, metal fume fever and pneumonia can be short-term issues. Longer-term, serious lung disease and cancer can occur if safety is now followed.
In small spaces, welding can cause the ignition of flammable materials, dust and vapours to cause an explosion. Great care is required to prevent such risks.
Poor ventilation together with the accumulation of gases can cause asphyxiation from lack of oxygen.
Radiation can be a problem, especially if the space contains reflective surfaces that give off glare and UV radiation. This can cause burns to the skin together with eye irritation.
To lessen the risk of these problems, the correct PPE should always be worn even in enclosed spaces. This will protect the welder and ensure no UV radiation or flash burns occur. It is also important to ensure the correct goggles and face shields are always worn.
Exhaust ventilation is essential to remove toxic gases and ensure there is sufficient oxygen for the welder. Observation of the time worked should also be carried out so that the welder gets regular breaks and has the opportunity to remove themselves from the environment. It may be a good idea to have more than one welder working and swap them around at regular intervals.
Why is Health and Safety in Welding so Important?
Welding is a dangerous job with many short-term and long-term health conditions for those that are not following the health and safety procedures. Health conditions are one of the reasons these procedures were introduced, and they are what keep welders and those working in close proximity safe.
Every country has its own health and safety procedures that must be followed when working in the welding environment. Some of the things that are covered in the legislation include:
Air Quality – Ensuring that there is sufficient extraction to get rid of the toxic fumes and other gases and dust.
PPE should be provided to ensure the workers are safe and protected. This includes protective clothing, face shields, gloves and goggles.
Checking the workstation and equipment to prevent shocks. Also ensuring safe working practices to reduce the risk of accidental shocks.
The Consequences of Not Following Health and Safety Guidelines
If the health and safety regulations are not followed, there can be serious health effects as a result. These conditions range from short-term to long-term conditions that can be serious and potentially life-threatening.
Irritation to the respiratory system including dryness of the throat, coughing and tightness in the chest
Acute irritant-induced asthma otherwise known as reactive airways dysfunction
Metal fume fever displays flu-like symptoms which last for a few hours after exposure to hot galvanised metals
Acute Pneumonia is caused by breathing in welding fumes. The fumes can cause a lung infection that can turn into pneumonia if left untreated. A vaccination is available but will not stop the infection, just reduce the risk
There is an increased risk of lung cancer for those welders that breathe in the fumes over a long period of time
Liver cancer is also linked to those who have long exposure to welding fumes without PPE
Arc-eye that can be both short-term and cause long-lasting effects
Hearing Loss caused by the welding and hammering
Flash burns that cause short and long-term problems
Working With Salamander Fabrications
Salamander Fabrications was established in 1968 in Huddersfield and is a full-service sheet metal fabrication company. They work with companies all over the world, producing high-quality fabricated metal products.
The company has grown over the years to include cutting-edge technology to provide high-quality products and an outstanding customer experience. Salamander now provides a complete range of CNC machining services as well as subcontracting and supplying a broad range of products to sectors and businesses.
As well as our range of high-quality services, we are also certified to the following standards:
ISO 45001
ISO 9001
We work for companies in many different sectors so we are always able to help with whatever the need may be. We have helped companies create the following products:
Construction and security offering the highest-quality products with a quick turnaround, designed and manufactured by experts.
Bespoke retail displays that can show off a company’s products to the fullest. These include features product displays, bar displays, retail display stands, portable displays and retail display cubes.
Working with the food and science sectors to create bespoke products made for their specific use.
Our work in the transportation sector includes vehicle construction, vehicle conversions, bridges and platforms, walkways, railings and public transit.
When you need an experienced and high-quality metal fabrication product, think of Salamander Fabrications. We have a friendly and highly trained staff who will be happy to help you. We pride ourselves on maintaining a high level of professionalism and safety for all of our staff and the companies we work with. This means we will be able to create the ideal product for your needs and ensure that it is designed and made to the highest standard. All you need to do is get in touch with the team today and speak to one of our friendly staff. They will be happy to help you and answer any questions you may have.
Looking to find out more about the best manufacturing processes for metals? You’ve come to the right place.
Here at Salamander Fabrications, we are a sheet metal fabricator specialising in creating high-quality metal products. With over 50 years of experience, we can undoubtedly say that our manufacturing processes for metals have been tried and tested, allowing us to create metal products for a wide variety of applications nationwide.
Interested in how the whole process works?
In this guide, we’ll break down:
How six key manufacturing processes work
What makes metal manufacturing so important
Common uses of metal fabrication
How Salamander’s expertise can benefit you and your project
So, if you’re wondering how different metals are manufactured – and the processes they require – you’re in good company. We’re going to explain everything you need to know about the many different manufacturing processes for metals.
To learn more about the work we provide or to get started with your next project, get in touch with our incredible sales team on 01484 843599 today – we’d be happy to help.
Key Manufacturing Processes Explained
We are experts in performing key manufacturing processes for metals with a great deal of care. Below, we’ll explain some of the most well-adopted processes in the industry.
If you require more information, or would like to take advantage of our sheet metal fabrication services, check out the techniques we use to deliver high-quality metal products for both large and small-scale projects.
CNC Machining
Here at Salamander, we provide a comprehensive range of CNC machining services. CNC machining is a computerised manufacturing process whereby a computer or pre-programmed software is used to control the movement of a machine or production equipment. At Salamander, we have CNC drilling capabilities in-house, but can help our clients with any part of the process they need!
In sheet metal fabrication, CNC machining is a shaping process, which involves using a machine to cut away material from solid metal in order to shape it. CNC machining in metal fabrication can be performed via several shaping processes: milling, drilling, and turning.
If you want aspects of the metal to be cut very precisely, CNC machining will come in handy.
Milling Process
In the milling process, the raw material is gradually removed from the metal until the required form or design is obtained by rotating multi-point cutting tools. The rotary cutting tool either slowly feeds the metal into it, moves over the fixed metal, or rotates with respect to both the metal and the tool.
CNC machines are used to attain the desired appearance of the metal workpiece.
Drilling Process
For drilling, a rotary cutting tool known as the drill bit is used to cut a hole in the workpiece material. To make a circular hole, the drill bit rapidly rotates while pressing on the metal. It works like a drill, hence the name.
Turning Process
Finally, turning involves rotating the metal on a lathe while removing metal along the diameter using a cutting tool that cuts in a precise, linear motion. This results in a cylindrical shape and form.
To produce different shapes and designs, the cutting tool can be turned and angled in various ways – this can be done manually or with a CNC turning.
Metal Folding
Metal folding is the process of reshaping metal without causing the material to break. The process works by forcing the metal to bend at an angle. Essentially, the process requires mechanical deformation to change the shape of the metal.
To alter the metal’s form beyond its yield strength (but below its tensile strength limitations), certain machines are needed to apply a degree of shear stresses to the material.
The most popular way to conduct metal folding is via a brake press, which pinches the metal to make creases in it. In this process, the metal is pressed against a punch that moulds the sheet metal while being held between the punch and a die.
Metal folding can also be carried out using a folding machine. A metal folding machine features:
A flat platform where flat sheet metal is securely placed
A clamping bar to secure the metal
A front panel that raises upward to bend the metal stretched over it
To carry out the fabrication process of metal folding manually, you could also use a hammer to hammer the metal until it bends eventually. However, this is a less precise method than using machinery or a brake press. For high-accuracy folds, we advise using a folding machine or brake press for your metal fabrication project.
Metal Cutting
Metal cutting is the manufacturing process whereby a piece of metal or material is cut into smaller pieces or components using one of the many cutting techniques. It is often the first, if not the only, process used in metal fabrication.
At Salamander Fabrications, we specialise in laser cutting to carry out the process of metal cutting. However, metal cutting can also be performed using:
Saw cutting (sawing)
Shearing
Plasma cutting
Waterjet cutting
And more
Cutting metal is one of the oldest metal fabrication processes, with sawing being the most traditional method. However, thanks to experts like Salamander, laser cutting is a more effective process for achieving precise cuts for a myriad of metals.
We implement laser cutting technology at Salamander to speedily and accurately cut sheet metals and create either finished components or fabricated metals for further operations. When fabricating sheet metal, laser cutting is typically the first stage of the process. It involves cutting the metal at specific places using an extremely powerful laser to produce designs and patterns.
The CNC system simply needs to follow the cutting route that is laid out in the product’s designs. Depending on the material, the laser beam will either melt, burn, or vaporise the targeted area in which it is directed at, producing a finished product with a high-accuracy cut edge and a quality finish to each of the cut components.
Metal Punching
Next up on our guide to manufacturing processes for metals, we’re going to explain metal punching. This is another one of the metal fabrication processes we specialise in, with a cutting-edge metal punch at our disposal. This process functions in multiple ways and is quite similar to laser cutting – only it doesn’t use a laser to complete a job and has some other differences.
Metal punching allows you to create holes in sheet metal or other filler materials using punch presses or sheering. By pressing incredibly hard on the material while pushing it between a punch and a die, holes will be created in the sheet metal. So, in more simple terms, punching involves applying a great amount of shearing force to a metal sheet that is between a punch and die to remove material from the metal sheet and create holes.
The finished result could be either the metal piece with holes for or the removed and shaped metal fragments that have been removed from the sheet, known as the blanking. In the process of blanking, you simply punch out flat metal components from a large metal sheet. The remaining sheet metal will have holes in where the metal components were punched out. The remaining sheet could be used for fastening purposes.
This process is associated with direct metal laser sintering.
Metal Stamping
The manufacturing process of metal stamping involves creating indentations in sheet metal using a machine press or manually with a hammer. This fabrication process is quite similar to metal punching, only it creates indentations in the metal rather than holes. Stamping is ideal for creating complex shapes, letters, and detailed designs in metal sheets and panels.
Rather than fully forcing the metal through the die, the turret simply raises it, creating an indentation – and not a hole. The two types of stamping presses that can be used include:
Hydraulic pressing
Mechanical pressing
Metal stamping machines can punch, cast, and cut metal sheets, as well as shape them.
The metal stamping process is relatively simple, yet the finished product looks high-quality and amazing. It involves placing a rolled metal sheet in a press that has a die in the preferred shape of the part.
Using a deal of force and compression, the die is then pressed into the metal using a press. A partly completed component is taken out once a set length of time has passed.
Blanking is often required in the early stages of the metal stamping process. Metal stamping can include blanking, piercing, coining, embossing and lancing – there are various types and processes for a number of applications.
Welding
Welding is one of the later stages of the sheet metal fabrication process.
Welding is where two or more metal components are combined to form whole metal structures. So, once metal has been cut, folded, or separated into parts, welding allows you to piece them together and create metal structures.
To adjoin multiple pieces of metal, a mixture of heat and pressure is required. So, welding works by joining two pieces of metal together, applying a great amount of heat and allowing the metals to cool. Pressure is often applied along the joint where the two parts meet.
Four main types of welding
Metal arc welding (GMAW/MIG)
Gas tungsten arc welding (GTAW/TIG)
Flux cored arc welding
Stick or arc welding
Stick or arc welding is also known as shielded metal arc welding (SMAW). It makes use of an electrode stick that, when in contact with metal, generates an electric current that creates an electric arc. The metal is joined together by the arc’s high temperature gradient.
Metal manufacturing is the practice of manipulating different metals to produce something new – we’ve explained many of the processes of metal manufacturing in this guide. It is one of the most versatile production processes on the market today.
Metal fabrication is important for a number of reasons – and without it, we wouldn’t have some of the many everyday applications we use today. From supplying the metal framework and beams for the buildings where we work, live, and socialise to creating household items like washing machines and fridges, most of the items we use on a daily basis would not exist without metal manufacturing, – at least not in their current form.
Metal manufacturing has played a huge part in the development of our society and many of the things within it, and it will continue to do so, regardless of what techniques and machines are used.
Working with Salamander Fabrications for Custom Laser Cutting Services
At Salamander Fabrications, we have a highly-skilled and experienced team of professional sheet metal fabricators who can carry out a complete range of sheet metal manufacturing processes for customers across the UK.
As one of the most trusted credible companies in the sheet metal fabrication sector, you can rest assured that our metal products are created with the highest quality standards, using the most proven and effective fabrication methods available.
Whether we’re working on large-scale manufacturing with molten metal, batch production works, or tailored, technical projects, we are professionals in combining quality with cost-effective production techniques for our customers. We are aware of how powerful steel, aluminium, and other sheet metals can be in producing reliable and consistent products.
To find out more about Salamander Fabrications and how our expert team can help with sheet metal fabrications for your project, don’t hesitate to get in touch today.
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