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.
You may have come across the term ‘laser cutting’ and thought to yourself: “what is laser cutting, and how does laser cutting work?” – perhaps that’s why you are here. Well, if you’re wondering what this fabrication process is, you’re in good hands. This is our definitive guide to laser cutting and all you need to know about it.
What is Laser Cutting?
Laser cutting is a non-contact fabrication process that uses a tiny, focused laser beam to burn through and cut materials like sheet metal, creating designs that are high-quality and dimensionally accurate. We are experts in laser cutting sheet metal at Salamander Fabrications.
As its name suggests, this manufacturing process uses a laser to cut designs in materials – this is a powerful laser beam that uses heat to burn, melt or evaporate materials to ‘cut’ them into shape. If you’re wondering “how does laser cutting work?”, we’ll explore the process below.
Using thermal heat to cut the material, the laser cutting process involves directing the laser beam through a nozzle to the material. When directed at the material surface, the laser head heats it until the target area of the material melts or evaporates. It’s this fusion of heat and pressure that allows the cutting action to occur.
Laser cutting is powerful enough to cut through various metals and non-metallic materials with varied thicknesses. Whereas other techniques require large machinery or equipment with immense power to be applied to the metal or material, laser cutting does the job without any contact. As a result, laser cutting is an efficient and durable sheet metal fabrication process. We hope this answered the question: what is laser cutting?
What Kind of Laser is Used
With our explanation of the laser cutter ticked off, let’s explain what type of laser is used. Four main types of lasers are used in laser cutting: CO2 lasers, neodymium lasers (Nd), neodymium yttrium-aluminium-garnet lasers(Nd: YAG) and fibre lasers.
Most laser-cutting companies and professionals use CO2 lasers when laser-cutting materials like metal; however, at Salamander Fabrications, we use fibre lasers for our laser cutting. We use a fibre laser because it is more efficient than other laser beams since it requires far fewer external gases and has less wastage. As well as this, fibre lasers allow for better and smoother cutting, quicker turnaround times and greater flexibility.
Fibre lasers are better than CO2 lasers for several reasons – but CO2 lasers are still widely used for the process of laser cutting. In the very first cases of laser cutting being used to cut sheet metals, CO2 lasers were used. In a gas combination that mostly contains carbon dioxide (CO2), helium, and nitrogen, the CO2 laser is generated. An electric discharge is used to electrically pump this kind of production laser.
Complex shapes and 3D shape designs are possible with laser cutting, but it must be done part by part. We can design custom shapes using our fibre laser beam and years of experience.
Laser Cutting vs. CNC Cutting
Laser cutting is one of the most effective metal-cutting methods out there, but it’s by no means the only one. CNC cutting and laser cutting are popular sheet metal fabrication procedures that are both high quality – however, they do have their fair share of differences and benefits.
CNC stands for Computerised Numerical Control. CNC cutting is a fabrication process whereby tools and machinery are operated by pre-programmed computer software. The process involves using a motion control system or computer to send a signal and CNC of the design to the cutting machine – where the technical design is then cut into a material. This process requires far more specialist tools and equipment than a laser cutter does.
Ultimately, the primary difference between laser cutting and CNC cutting is how each method goes about cutting a material – they each cut metal in their own way. Unlike traditional CNC cutting which relies on specialised tools to carve out the pattern, laser cutting uses a powerful laser beam to burn through and vaporise the metal material.
Laser cutting has higher speed and high-precision cuts
Compared to CNC cutting, laser cutting works twice as fast. A laser cut machine makes it simpler to construct thick pieces and cut material in one go. Manufacturing durable and accurate components does not necessitate a workpiece or physical force.
Another major benefit of laser cutting when compared to traditional metal cutting methods is that it allows for higher precision cuts and enables users to design curves and corners dimensionally accurately. While traditional CNC cutting uses tools with limited widths (an average radius of just less than 1mm, laser beams can have a radius as tiny as 0.1mm. As a result, laser cutting allows for more detailed cuts and intricate designs. It has no design limitations.
Some additional benefits of laser cutting include:
Can be cheaper thanks to no tool wear and less wastage
What Can Laser Cutters Actually Cut?
We’ve answered “how does laser cutting work”, but many people also wonder what laser cutters can actually cut. Well, laser cutters have wide material compatibility and are suitable for various types of materials. There is no other technology or tool that can fabricate and cut as many types of materials as a laser cutter can.
Our laser cutters are most often used to cut aluminium and mild or stainless steel at Salamander Fabrications since we specialise in producing products from sheet metal. Nevertheless, depending on the method you use or the industry you work in, laser cutting can be employed in a variety of fields for an extensive range of materials. Get in touch with us today to find out more about how our laser-cutting services can help.
Laser cutters can also be used to cut through most organic and thicker materials which include:
Metals
Wood, paper cardboard and cork
Some plastics
Acrylic
Teflon
Rubber
Cloth
Leather
Laser cutters can cut all types of metals, which is why they are a top solution for sheet metal fabricators like us at Salamander Fabrications. They can cut anything from mild steel and carbon steel to stainless steel and nonferrous metals. At Salamander Fabrications, we use copper and brass regularly in our work, in addition to steel and aluminium.
If you want a 3D model or some intricate models created, laser cutters can make the most complicated shapes on various materials without large-scale manufacturing machines.
Importance of safety when working with laser cutters
Although reflective metals like silver can be cut by a laser machine, they can be trickier to work with than other metals as they run the danger of reflecting laser beams, albeit this is a minor risk.
Other materials, including glass and ceramics, can be etched with a laser in conjunction with being cut. However, you must take extreme caution when utilising plastics as some plastics can melt, burn, catch fire or even release dangerous gases – as well as cause harm to equipment.
FAQs about Laser Cutting
Now you have a much better idea of what laser cutting involves and what it can do, let’s answer some of the most frequently asked questions regarding laser cutting.
Which laser is used in laser cutting?
There are a few different types of lasers used in laser cutting, such as CO2, Nd and Nd: Yag lasers. However, we use fibre lasers for all of our laser cutting projects here at Salamander Fabrications because fibre lasers provide smoother cutting, quicker speeds, greater flexibility, and less waste from our projects thanks to their increased efficiency.
What are CO2 lasers used for?
CO2 lasers are most commonly used for skin and dermatology. A CO2 laser cutter is most frequently used to cut materials like wood, cardboard, paper, cork and some plastics. A CO2 laser cutting machine relies on a focusing lens to direct the CO2 laser beam on the localised area of a material.
Does laser cutting require oxygen?
An assist gas, which may be active or inert, is required for laser cutting. The typical active assist gas for laser cutting carbon steels and metal is oxygen. Oxygen is often known as the cutting gas by many.
Is laser cutting harmful?
When exposed to a laser beam, you could suffer from skin burns or extreme eye damage. If used improperly laser cutting can inflict severe injuries or cause fires. However, laser cutters pose very little risk and are extremely safe when used appropriately and properly. To avoid any harm, ensure you use laser cutters as directed.
How deep can a laser cutter cut?
The laser beam will completely penetrate and cut right through the material if more heat is applied to the targeted area than can be dissipated by heat conduction. Although some laser cutters can cut material up to 20 mm thick, the majority of machines operate on materials that are closer to 0.5–12 mm in thickness, based on the type of cut being performed.
Working with Salamander Fabrications for Custom Laser Cutting Services
Are you interested in our work or require this procedure for an upcoming project? To learn more about laser cutting and the work we carry out – or to begin your next project with Salamander Fabrications, don’t think twice to get in touch with our remarkable sales team who can give you the support you need. Just give us a call at 01484 843599 or email us at sales@salamanderfabs.com today! We’d be more than happy to help.
When it comes to finishing and protecting your sheet metal fabricated products, powder coating is one of the best options on the market! But what is powder coating? How does it work? And why should you choose it?
At Salamander Fabrications, we’ve been mastering the craft of powder coating on our metal fabrication projects for over four decades. At this point, we’d confidently say there’s nothing we don’t know about the process and are committed to ensuring our customers can rely on our quality sheet metal products for years to come.
In this guide, we’ve rounded up our expertise and put together everything you need to know about powder coating. You’ll find out:
What powder coating is
Exactly how the powder coating process works
Different types of powder coating available
Choosing the right colours and finishes
The pros and cons of powder coating vs paint
Got a specific query? If you’d like more than just to read about it, get in touch with our friendly team on 01484 843599 or at sales@salamanderfabs.com and we’ll be able to give you tailored advice to meet your precise needs.
What Is Powder Coating?
Powder coating is a colour-finishing technique used on thousands of different everyday materials, including sheet metal, concrete, steel and plastic surfaces.
Powder coating is often used instead of traditional liquid paints. It can be used indoors and outdoors, and offers a high-quality, long-lasting and durable finish to products of all shapes and sizes!
Examples of powder coating application for everyday products:
White goods like fridges and freezers
Stands and display units
Cars and auto assembly parts
Indoor and outdoor furniture
So, How Does Powder Coating Work?
Powder coating, as the name implies, uses a dry powder instead of traditional paint. This powder is sprayed onto the objects to be coated and is then heated and cured to form a harder, thicker and more consistent coating than painting.
This protective coating can be used in indoor and outdoor applications. It continues to be extremely popular as a manufacturing process due to it ticking many boxes. It is:
Water resistant
Heat resistant
Weather resistant
Corrosion resistant
Impact resistant (to a degree)
It also creates a uniform finish and a customised visual appearance.
The Powder Coating Process – What Is Powder Coating Application?
Powder coating is a dry finishing process that can be carried out on many different products or structures. As sheet metal fabricators, we at Salamander usually work with powder coating on metal, but it can also be applied to other materials such as concrete, plastic, etc., to protect them from the elements.
Powder coating requires a considerable amount of equipment, but the process itself is relatively simple. Broken down into five easy Cs:
Step-by-Step Powder Coating Process
Cleaning – The material surface needs to be manually cleaned, as well as go through a chemical cleaning. This ensures that any grease, dirt, imperfections or oils have been removed and that the surface is as smooth as possible. This will help the powder coating finish stick to the structure.
Coating – The product is then coated, usually using a powder coat gun, which is a type of spray gun. Polyester powder coating (or other materials) uses an electrostatic gun application method, which coats the entire surface of the product.
Charging – The metal product is connected to a power unit, which helps the powder particles attach to the metal as they are shot out of the gun. The power unit gives off an electrostatic charge, and the powder particles are then attracted to this charge, helping them stick for a smooth finish.
Curing – Finally, the coating is cured, which is where a chemical reaction takes place. During the heat curing process, the powder melts slightly and bonds with itself to create a strong coating. In some cases, powder finishes also bond with the metal to improve the durability of powder coats. This curing happens in a specialist ‘oven’, which heats the coated surfaces to around 200°C for 20 to 30 minutes (product dependent).
Cooling – The structures are then allowed to cool which further strengthens the bonds before they are ready to be shipped out. The dry powder coating process is now complete!
Different Types of Powder Coating
Sometimes, the question ’what is powder coating?’ isn’t as easy to answer, as there are so many different types of powder coating! Depending on the type of finish needed, powder coating can be made with a few different materials. Polyurethane, epoxy, polyester and acrylic are some examples of commonly used powder-coating materials.
Thermoplastic coatings become liquid during the heating process, which means they don’t actually chemically bond to the object being coated. This makes the coating reusable, reversible, and thinner than thermoset powder coating.
For objects that might need to be recoloured, recycled or reused in a different context, thermoplastic coatings are a better option.
Thermoplastic coatings typically provide a thicker layer, which makes them more durable when compared to thermoset powders. This type of coating is used more regularly on household items, automobile parts and metal objects.
Thermoset Coating
Thermoset coatings are a thinner type of coating. When cured, thermoset powder chemically bonds to the material it is coating, which means that it cannot be recycled, but also makes it less prone to chipping or cracking.
The key advantage of thermoset powder coating is that it is incredibly heat resistant, so it’s very suitable for protecting metal structures in high-heat areas.
Choosing the Right Colours and Finishes
One of the advantages of powder coating is the incredible range of colours and finishes that are available. Most powder coating providers will stock a range of colours (using RAL colour codes), making colour ordering quick and easy! Each RAL colour is also available with a few different levels of gloss, creating even more options!
Gloss particles can be added to most colours to provide different levels of shine. Unlike RAL colours, however, gloss levels are not uniform across manufacturers. It’s the brand of coating powder used that will impact what gloss and textures are available to you.
The team at Salamander Fabrications are highly experienced and can work with you to create a finish that works perfectly for your products, regardless of colour or brand!
Gloss Finish
Gloss finishes are the most popular in the industry, and have a gloss level of about 70%.
This kind of powder coating has a great level of shine and you can see reflections of most things, though they aren’t super-defined. It isn’t a mirror finish, but it does have a lovely reflective surface.
It is also very easy to clean due to the smooth surface!
High Gloss Finish
A high gloss finish will help your structures stand out no matter what! These surfaces have gloss levels of above 80% and offer a smooth, incredibly easy-to-clean surface.
Important to note, however this application process will result in visible imperfections if the underlying material isn’t completely smooth. This means that more surface preparation is required before the process of powder coating can be carried out.
Matte Finish
Matte or flat powder coating has a low gloss level – usually around 30%. It will reflect light in some capacity, but you won’t be able to see clear reflections, and only in high levels of light.
That the matte coating nullifies reflection to this degree is great for products that might have some smaller surface imperfections on the metal – they will be hidden. However, matte coating can be harder to clean than some glossy surfaces so this is worth bearing in mind.
Matte coating is great for use in areas like offices and retail as, though cleanliness is important, the standard is not incredibly rigid. However, in industries – such as the science or food industry, where powder coating is commonly used – where cleanliness is of great importance or where cross-contamination is possible, a matte finish is less ideal. This is because the textured matte surface can have tiny crevices or dips, which make it trickier to clean.
Sand Texture Finish
As well as matte, gloss and high-gloss finishes, texture can be added to powder-coated products. Like matte finishes, textured finishes are great for hiding any imperfections in the underlying product surfaces and are also great for providing additional tactile support (improving accessibility) and grip/friction (particularly on outdoor surfaces).
Sand texture is the least obtrusive texture and is fairly similar to matte textures. Sand texture, like the name implies, feels like sandpaper to touch.
Wrinkle Texture Finish
Similar to sand texture, wrinkle texture is slightly rougher. It has a lot of surface area due to raised grooves, bumps and wrinkles in the surface texture. This makes it excellent for use outdoors and provides a strong level of grip where needed. Wrinkle texture is usually the roughest option when powder coating products and is great for use in industrial applications.
Hammered Texture Finish
Hammered texture finishes have a similar level of texture to wrinkle textures, but with a higher gloss finish. It is very durable and allows customers to request a gloss finish without having to worry about any imperfections on the metal surface of the product.
For this reason, it doesn’t need as much surface preparation when compared to gloss coatings.
Powder Coating vs. Paint
One of the follow-up questions we often hear after ‘What is powder coating?’ is ‘Is it better than conventional paint?’, and it’s a good question!
There are lots of different factors that can affect which coating is the right one for your project, but, in general, spray painting is more affordable upfront, while powder coating is a more efficient, high-quality and long-lasting product.
Durability – One of the biggest advantages of commercial powder coating over spray paints is the protective feature that powder coating technology provides. Powder coating creates a hard, solid layer that encases the object it is applied to and protects it from heat, cold, ice, water, UV rays, bumps, scratches and dents. Powder coats are not only more durable than paint coats, but they also help fabricated products last longer.
Environmental impact – Unlike some traditional spray paints, powder coating doesn’t release volatile organic compounds (or VOCs) into the air. It’s actually a very eco-friendly process, as any excess powder can generally be reused, and thermoplastic coatings are also recyclable!
Range of colours and textures – There is a vast range of powder coat colours and textures. While spray paint finishes also have a range of colours and gloss/matte options, there is no way to emulate sand, wrinkle, or hammered textures with paint.
Cost efficiency – While paint coating is cheaper upfront, powder coating services are very cost effective when looking at their lifetime cost. While the process of application and protective gear needed for powder-coated parts is more expensive, the lifetime costs are relatively similar.
Wastage – There is also considerably less wastage associated with powder coating, as excess powder or powder that doesn’t stick during the coating process can be reused again. With spray paint, any wastage is lost and cannot be reused.
Quality of finish – As powder coating uses electrostatic processes to cure the coating, the finish is generally smoother and more consistent. When painting an object, the paint may run down the sides or be coated unevenly, whereas powder coating guarantees a smooth metal finish.
Powder Coating with Salamander Fabrications
At Salamander Fabrications, we’ve been working in sheet metal fabrication and the powder coating industry for over 50 years. We pride ourselves on our expertise and attention to detail when it comes to all aspects of the projects we undertake, including powder coating metals to help strengthen them, protect them and create a high-quality finish.
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.
By nature, the construction industry comes with risks. Construction workers are regularly handling hazardous materials, working at heights, carrying heavy loads and working in environments that pose long-term health risks. This means that the rules and regulations surrounding health and safety in construction are – and need to be – incredibly stringent and comprehensive and should be followed by every single person on-site.
Employers, site management, contractor clients, and business owners all have a duty of care to those working on their sites to protect them from hazardous substances and safety risks wherever possible. This is where the extensive range of safety requirements and safety regulations for the construction industry come in.
At Salamander Fabrications, we work with a wide range of organisations in the construction industry to improve safety processes and help site managers meet the legal requirements asked of them. Our products have helped ensure the safety of workers all over the country for decades. We’re experts in designing and creating products that help to support safety professionals to ensure that construction activities of all kinds can be carried out safely and efficiently.
To learn more about how we can use sheet metal fabrication services to help support safety management in construction or to learn more about health and safety in construction, keep reading!
The Importance of Site Health and Safety
The Health and Safety Executive (HSE) is the regulator responsible for health and safety in the UK. There are health and safety requirements in every industry and the key principles are very similar in many instances. HSE regulations cover not just physical health and preventing injuries to workers but essential health/daily health, mental health/psychological health, environmental management, work-related illness, the control of hazardous substances and workplace hazards, and the duties of employers to protect workers from all of these, among others.
Health and safety on construction sites are of the utmost importance, as there are significant unavoidable risks that are part and parcel of working in construction. Health and safety regulations exist to minimise these risks and prevent potential accidents from happening as much as possible. Deaths on sites and injuries on construction sites are always a possibility, which is why site health and safety exist – to prevent work-related accidents and keep all workers safe while they do their jobs.
How poor health and safety can impact construction businesses
As well as the risk to safety and life on construction sites, incidents, injuries and sickness can also reduce the productivity and profitability of a business. By improving safety, you reduce the likelihood of incidents and allow site workers to get on with their jobs safely and efficiently.
A lack of relevant health and safety provisions also opens organisations up to considerable legal challenges. Health and safety regulations are, more often than not, enshrined in law. This means that not following them is illegal, and the penalties for doing so can be heavy. Companies not following health and safety regulations are likely to invoke hefty fines from the HSE, and in more severe cases organisations can have their memberships and accreditations from industry bodies revoked, or even be banned from operating. Companies are also open to civil suits from employees, their families, or members of the public who have been affected by errors made by companies.
Key Risks to Health and Safety in Construction
There is an extensive list of health and safety legislation that must be followed on construction sites (more on that later!), but there are five key categories which make up the majority of incidents on construction sites today. Companies need to take special care when it comes to these incidents in particular:
Falls from height – responsible for 50% of fatalities on construction sites and 19% of non-fatal injuries (over double that of all industries).
Being trapped by something collapsing or overturning – responsible for 13% of fatalities.
Slips, trips or falls on the same level – responsible for 26% of non-fatal injuries.
Being struck by a moving, falling or flying object – responsible for 12% of non-fatal injuries and 11% of fatalities.
Equipment needs to be tested and analysed to ensure it is as safe as it can be and passes all safety assessments. All equipment should work to minimise risk to workers and to do this in the best way possible. Equipment should also be maintained regularly, and all equipment that needs it should have strict maintenance processes and schedules to ensure that safety law is followed and the risk of injury is as low as it can be.
As well as having the right equipment to carry out the job required of them workers must be able to recognise hazards on-site. Health and safety inductions for all staff should be comprehensive and carried out by a qualified and competent health and safety specialist. Workers should also be upskilled on their health and safety knowledge at any given opportunity – not only does this benefit individuals and provide them with job satisfaction, but it also means that issues are likely to be picked up considerably faster, allowing site owners and managers to rectify them before they cause an incident.
Creating a Consistent Strategy for Health and Safety in Construction
Comprehensive health and safety doesn’t just happen overnight. It requires a complete strategy based on relevant legislation and a safety culture that puts workers and their health first. Risk assessments and method statements are required to understand how to build safe systems on each unique site. The legislative requirements of different sites and projects will impact the overall health and safety strategy that is implemented, and shortcuts cannot be taken in this area.
Key Rules and Regulations in the Construction Industry
There are hundreds of different pieces of legislation that go into health and safety in construction, which is why making a safety plan can be a complex task! These are some of the most important pieces of legislation that anyone working on or with a construction company should be aware of:
The Health and Safety at Work Etc Act– the Health and Safety at Work Act is not a specific set of regulations, but it is a piece of legislation that covers many other specific health and safety regulations and is how those regulations are enforced in law.
The Health & Safety (First Aid) Regulations – these regulations apply to every workplace in the country. However, because the construction sector is a higher-risk environment, there are additional first-aid requirements in place.
The Manual Handling Operations Regulations – these regulations cover the processes required for safe lifting and carrying at work, something that is key for almost every construction site!
The Health & Safety Signs and Signals Regulations – signs and signals to warn construction workers of different hazards are standardised in the UK so that everyone clearly understands the safety measures that must be taken in different areas of a site.
The Management of Health & Safety at Work Regulations – this is a key set of regulations for employers. This set of regulations applies to every workplace and requires risk assessments to be carried out and for those risks to be managed and mitigated wherever possible.
The Control of Substances Hazardous to Health Regulations – also known as COSHH, this is not an exhaustive piece of legislation, but many harmful materials have rules on how they should be handled, and they are laid out in these regulations.
The Working at Height Regulations – As we’ve discussed, working at height is one of the riskiest parts of work on a construction site. The Working at Height Regulations are intended to minimise the risks associated with working at height wherever possible and need to be followed strictly by all construction workers and employers.
The Supply of Machinery (Safety) Regulations – UK manufacturers are required to comply with this piece of health and safety legislation, and to have their machinery inspected, if necessary. At Salamander Fabrications, these regulations are something we work in full compliance with. This is particularly important when supplying to the construction industry, something we have extensive experience with.
Metalwork and sheet metal fabrication are industries that have been around in some form or another for hundreds of years! Modern sheet metal fabrication involves a range of metal fabrication techniques and can use many different types of sheet metal. In fact, it’s one of the most versatile production processes on the market today.
Because of how versatile the processes and techniques associated with sheet metal fabrication are it is easy to get confused! That’s why we’ve created this guide to all the basics of sheet metal fabrication, what it means, the different stages of the process and what fabrication services can be used for!
To find out more keep reading or get in touch with Salamander Fabrications! Our expert team are on hand to help with any questions you might have or to help you get started on your next sheet metal fabrication project.
What is Sheet Metal Fabrication? What does it mean?
Sheet metal fabrication can be used as quite a broad term that encompasses several different production processes. When you hear the term “sheet metal fabrication” it can be referring to one of two things:
The entire fabrication process, which features a range of different steps and processes to create metal products.
Any of the steps within the manufacturing process including cutting, punching, bending, welding, assembly, powder coating and other forms of metal fabrication.
The purpose of this type of manufacturing is to produce a wide range of different parts for use in a wide range of industries. To assemble these components both small and large, techniques like welding are often used to create strong bonds and ensure that they remain intact during their lifetime.
Sheet Metal Fabrication Uses
One of the biggest advantages of sheet metal fabrication is the sheer number of products and parts that can be created! While there are some restrictions on what can be done the vast majority of the designs we receive can be created using sheet metal fabrication processes!
As a precision sheet metal fabrication company we work with companies in hundreds of different sectors including transportation (automotive and aerospace), construction, health and safety, food processing, science and technology, consumer, retail and leisure, to name just a few!
Custom sheet metal fabrication can be used to produce products which require mass production and high volume, but also incredibly technical, precise, and complex metal products which makes sheet metal services incredibly versatile. The high level of precision combined with the high level of efficiency makes sheet metal one of the most diverse and popular methods of production for many organisations and suppliers.
Sheet Metal Fabrication Techniques – the Stages of Production
Sheet metal fabrication services can be easily tailored to the needs of whatever project it is we’re working on.
As we’ve discussed, there are several different steps involved in the steel metal fabrication process, which helps fabricators to create a wide variety of different objects, from bespoke screws, hinges and components to larger structures like sheet metal enclosures and other custom sheet metal parts, as well as meeting the design specifications for thousands of different products.
Some projects will only require the input of metal fabricators for one or two stages of the process, while others will require end-to-end production, from design to delivery.
Designing
The design stage is the first step in any sheet metal fabrication project. Starting with a comprehensive design process helps to set any project up for success. Concept design for metal components is usually done using digital design software like CAD design. This is an area we specialise in at Salamander Fabrications, and we have a wealth of industry experience to draw on when it comes to creating quality bespoke designs.
CAD designs can show the shape, size, colour, and dimensions of a finished product in both 2D and 3D formats, taking many careful design considerations into account. However, CAD engineering design also contains a wide range of technical data and requirements which are compatible with advanced manufacturing solutions and machinery. This means that when designs are approved, they can be instantly input to CNC laser cutters and punching/bending machines, speeding up the production process significantly.
In addition, bespoke design briefs like these contain information on the sheet metal materials to be used (mild steel, aluminium alloys, yellow metals etc.), as well as the processes needed to create the product, tolerances and dimensions of each of the product parts, and any assembly services required.
The success of the entire project rests on the quality of the design so it’s incredibly important to get it right – from design to prototyping – before moving on to manufacturing services.
Laser Cutting and Metal Punching
Laser cutting and punching are the processes that allow our team of fabricators to turn metal sheets into templates that can then be bent, pressed and welded into their final form. We work with a variety of materials, including mild steel, stainless steel, aluminium sheets and some yellow metals. We can also work with a wide range of metal thicknesses, in line with the designs of your product.
Laser cutting uses fibre or CO2 lasers to cut out shapes or cut holes, forms and spaces in metal sheets. This sets out the key forms and shapes of the pieces of metal and does it quickly, cleanly and smoothly.
A metal punch is another one of the metal fabrication tools at our disposal. It works similarly to laser cutting in many ways but uses mechanical means to get the job done rather than using a laser.
Using both laser cutting and punching technologies in-house allows us to carry out every job in the most efficient way possible, which helps us maintain a competitive price.
Bending and Press Brakes
Once sheet metal has been cut it is then bent and folded to create 3D structures from 2D sheets of metal.
CNC press brake machines are used to accurately bend and shape the metal into the right dimensions before they are welded together.
For smaller, more precise elements of metal fabrication, spot welding can be used to create multi-piece metal structures.
Assembly
The assembly stage of a sheet metal fabrication project is often one of the most complex steps and needs an experienced assembly department to ensure the safety of products with electronic components. As well as the installation of electrical components, the assembly stage also includes:
Quality testing
Electrical safety testing
Secure packaging
Delivery to the customer
Complex assembly should only ever be carried out by experts with the skills to install electromechanical parts and ensure the longevity of these products once they leave the metal fabrication plant.
Powder Coating
Powder coating is one of the last steps in the process of sheet metal fabrication. Not all metal structures need powder coating but it can be used to help prevent wear or corrosion of steel and aluminium, particularly if structures are going to be used in outdoor environments or cold and damp environments.
During the powder coating process, an electrostatic powder is applied to the metal pieces and is then heat cured. The result is a hard-wearing and waterproof coating to the metal which comes in a range of surface finishes.
Powder coating can have a matte finish or gloss finish and comes in almost any colour you could choose, which also makes it perfect for “branding up” structures to be used in stores and offices, or for promotional materials.
The Sheet Metal Fabrication Process with Salamander Fabrications
At Salamander Fabrications our experienced team are professional sheet metal fabricators, passionate about exceptional quality standards and great British manufacturing.
We’re experts in the combination of quality alongside economical production methods for our customers whether we’re carrying out large-scale production, batch production jobs or bespoke, technical projects. We know how effective steel, aluminium and other sheet metals can be when it comes to creating a durable product that is fit for purpose every time.
To learn more about sheet metal fabrication and how our dedicated operations team can help bring your products to life, please don’t hesitate to get in touch! Our friendly team are always on hand to help kickstart new projects and get you the products you need.
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