The metal fabrication market in the U.S. was valued at US $362.4 Bn in 2020 and is expected to cross US $473.7 Bn by 2031. In terms of raw material, the iron & steel segment constituted key share of the metal fabrication market in the U.S. in 2020. There are over 77,023 metal fabricators currently employed in the United States.
Metal fabrication companies build machines and parts from raw steel and metal materials. The process includes use cutting, burning, welding, machining, punching, forming, and different assembly types to create a product for industrial applications. Metal fabrication projects include everything from hand railings to heavy equipment and machinery.
“Light fabrication” includes fabricated metal products such as furniture, cabinetry, gratings, hand tools, firearms, electronics, and other smaller products.
“Heavy fabrication” processes include production of structural building materials, airframes, ship hulls and other large materials. “Heavy fabrications” are the foundation of many structures and infrastructure utilities like bridges and tunnels. Steel reinforcement of buildings are now common in construction projects. Components required in these applications are VERY large, and heavy fabrication facilities must be large and open enough to accommodate them.
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Regardless of the size, metal fabrication has seven basic steps from design to assembly. Here is general overview of the metal fabrication process:
- Design - Metal fabricators work with customers to create project diagrams by hand or CAD software.
- Prototype - Metal fabricators create a prototype before full production to ensure quality and application.
- Program - CAD designs are translated into computer-controlled machine designed to automate the process.
- Cut - Common cutting techniques include laser cutting, mechanical shearing, and water jet cutting.
- Form - Metal fabricators will bend the metal into the desired shape. How the bend the metal depends on the project and can include folding, bending, stamping, punching, machining, and other methods.
- Finish - Once the shape is formed, metal fabricators finish the product by using refining or coating methods.
- Assembly - If required, metal fabricators weld or incorporate other elements for final assembly.
Once the scope of work for a project is determined, a process flow example is shown below
A A metal fabrication company with the latest equipment and technology ensures accuracy and quality and avoids delivery delays. A basic list of equipment found in a metal fabrication company includes:
- Brakes & forming equipment
- Welding equipment
- Precision Turret & Laser Cutting
- CNC machining lathe & mill
- Software ERP & engineering
- Paint and powder coating
- Quality control equipment
As with every industry… old, out-of-date equipment production can be problematic. It is important to work with a metal fabrication company that utilizes the most advance technology.
Examples of advanced equipment
KEYENCE Wide-Area Coordinate Measuring Machine.
Highlights:
- Accurate measurements over a 32’ x 16’ x 16’ areas.
- Easy 3D and GD&T measurements.
- Portable and shop floor ready.
- Automatic inspection reports.
HAAS VF9- 7500
This workhorse is well suited to high material removal rates, no matter what kind of cut you’re taking. The standard 7500 rpm 50-taper spindle has 30 hp, and the 2-speed gearbox delivers 450 ft-lb of torque at 500 rpm. This is perfect for drilling large holes, using wide shell mills, and any other demanding application. 84”x40”x30” travel for those larger parts.
HAAS DM-2
The DM-2 is a compact, high-speed machining center built with proven Haas components and sub-assemblies. The machine’s shop-proven 40-taper inline spindle, 18+1 tool changer, high acceleration rates, fast rapids, and impressive short tool-change times make the DM-2 an attractive high-productivity machining center.
The DM-2 allows shops to use their existing 40T tooling and enjoy the benefits of a larger spindle, and its lean-style, compact footprint makes very efficient use of valuable shop floor space. 28”x16”x15.5” travel for those smaller parts.
HAAS TM-1
Haas Toolroom Mills are the true definition of value, providing full CNC capabilities – including available 4th- and 5th-axis functionality. They offer the perfect combination of value, reliability, and performance for any shop – from schools to high-end manufacturers. 30” x 16”x 16” travels.
Vectis Cobot Robotic Welding Machine
Welding automation thrives on consistency of parts via fixturing, joint cross-sectioning, acceptable material conditions, consumables condition, etc. Repeatability is programmed on a “master part” and then simply repeated by the arm in production. This will reduce lead times, increase capacity, side step welder shortages, increase repeatability, reduce post ops due to clean welds, increase quality, improve safety and operator fatigue.
Hyundai-Wia HD2600SY CNC Lathe
Hyundai Wia, one of the largest machine tool makers in Korea, developed the HD2600/3100, which delivers high-performance, high heavy cutting capability, and maximum productivity.
Features:
- Integrated processing through synchronized control of Main/Sub spindle ("SY" Type)
- Box guideways for heavy duty cutting
- 30° slanted one-piece bed structure for high rigidity
- Stabilized Unit Structure to minimize thermal displacement
- Multi-tasking operation with wedge type Y-axis BMT55P turret
The team at MaRCTech2 understands that more than technology and equipment is needed. That is why we have chosen to work with companies which have excellent customer service programs and decades of success.
Our metal fabrication manufacturer has a world class ERP system, and each project is handled by first class, concierge-style customer service representatives and provides abundant metrics and details on your Work in Process (WIP) and delivery status updates.
With current space and inventory management costs at all-time highs, they can build your blanket orders per Material Requirements Planning (MRP) and store them on site for just-in-time delivery management. Minimize your risk and assure those pesky cycle counts, and rental storage fees are a thing of the past.
We pride ourselves on representing a true, full-service metal fabrication supplier that flows from engineering to shipment, while providing lean manufacturing techniques and superior customer service so you get the best value for your dollars.
We are happy to share our complete list of manufacturing resources which includes a premier full-service machine shop specializing in precision metal manufacturing, sheet metal services, and NPI manufacturing. Introduce yourself and get immediate access.
