The Importance of Understanding Sheet Metal Fabrication Techniques

Sheet metal fabrication is an essential process for many industries, enabling the creation of complex and precise metal components. Understanding the various fabrication techniques is crucial for effective decision-making, cost optimization, and quality control. In this guide, we’ll explore the key sheet metal fabrication techniques, their advantages, and their applications. By the end, you’ll have a solid understanding of the options available to you, empowering you to make informed choices for your organization.

Sheet Metal Fabrication, Explained

What is sheet metal fabrication, exactly? It’s the process of transforming flat sheets of metal — like aluminum, steel or stainless steel — into desired shapes and forms. It involves a combination of cutting, bending, forming, and joining techniques to create components used in various industries, including the automotive, aerospace, and construction sectors, among others.

Types of Sheet Metal Fabrication Techniques

As mentioned above, there are a variety of techniques used during the sheet metal fabrication process. Let’s take a closer look at each of them.

Sheet Metal Cutting Techniques


Shearing is one of the most basic and widely used sheet metal cutting techniques. A shear is basically a pair of blades used to make straight cuts into sheet metal, and is most suitable for thin- to medium-gauge sheet metal.


Sawing is another traditional metal cutting technique. It employs a saw blade to cut through metal, and is best for making curved or irregular cuts on thicker sheet metal.

Laser and Plasma Cutting

Laser and plasma cutting machines are typically controlled by computerized systems, allowing them to achieve high precision and versatility. Laser cutting involves using a high-powered laser beam to melt, burn, or vaporize the material along the desired cutting path. Similarly, plasma cutting utilizes a plasma torch to cut through electrically conductive materials.

Waterjet Cutting

Waterjet cutting employs a high-pressure stream of water — often mixed with an abrasive substance — to cut through sheet metal. This method is great for a wide range of materials, especially those that are sensitive to heat.

Sheet Metal Bending and Forming Techniques


As you might have guessed, bending is a common way to manipulate sheet metal. It’s typically done with a machine called a press brake, which applies force to deform the metal along a predetermined bend line.

Roll Forming

Roll forming is a continuous bending process used to create long metal strips with a consistent cross-section. The metal goes through a series of rollers, which gradually bends it into the desired shape.

Stretch Forming

Stretch forming is a metal forming process wherein a metal sheet or extrusion is stretched over a die to create complex curved shapes.

Joining and Fastening Sheet Metal


Welding is a widely known technique for joining sheet metal. It involves melting the edges of two or more metal pieces and allowing them to fuse together.


Riveting is a mechanical fastening method that involves using a rivet to join two or more sheets of metal. The rivet — a metal pin with a head on one end — is inserted through holes in the sheets, and the other end is deformed to create a second head, securing the sheets together.


Clinching, also known as press joining or press fastening, is a method that creates a mechanical interlock between two or more metal sheets. It involves pressing the sheets together with a die and punch, forming a permanent connection without additional fasteners.

Seam Locking

Seam locking joins two metal sheets by folding and interlocking their edges. This creates a common and secure connection, and is often used in the HVAC industry for ductwork fabrication.

Finish and Surface Treatment of Sheet Metal

Powder Coating

During the powder coating process, a dry powder is electrostatically applied to the sheet metal surface. The powder adheres to the metal and then is heated to create a durable and protective coating.


Anodizing is an electrochemical process that is most commonly used on aluminum sheet metal. It creates a protective oxide layer on the surface of the metal, which improves corrosion resistance and provides a decorative finish.


Polishing is a common mechanical process that smooths the surface of sheet metal and gives it a shiny appearance. It involves using abrasives and polishing compounds to remove imperfections and scratches, which results in a smooth and shiny surface.

Work with CR Metal Products for Your Sheet Metal Fabrication Needs

This is by no means an exhaustive list of all the sheet metal fabrication processes available to businesses like yours. However, these are the most common types of methods used to create specialized products. If you have questions about these processes, the experts at CR Metal Products would love to answer them.

We’ve been in business since 1946, making us well-versed in the custom fabrication and manufacturing sphere. Now, we’re one of the leading providers for custom manufacturing and finishing services in the United States. We also maintain an ISO 9001:2015 certification, which holds us to the highest standards in manufacturing excellence.

Connect with Us Today

If you’re ready to get started on your next fabrication project, connect with our team today.