Sheet metal forming is a process used in many industries to make metal parts from thin metal sheets. It’s actually one of Xometry's most popular manufacturing methods. Our customers use the Xometry Instant Quoting Engine® to get automatic quotes on everything from simple brackets to aircraft parts and sheet metal assemblies. In this article, we’ll give you the lowdown on sheet metal forming, including the various processes, suitable materials, and its pros and cons.
ACE Product Page
Also known as sheet metal fabrication, sheet metal forming uses metal sheets to make various products and components. The metal sheets are formed and cut into the necessary shape and size via many different processes and equipment, which we’ll cover a little further down. The material then goes through any necessary finishing steps, like surface treatment, deburring, or welding.
The reason for this process’s popularity is that sheet metal is both tough and malleable, making it easy to manufacture different parts that, despite being bendy and lightweight, are still strong and durable. It’s not limited to just food and drinks cans, however; almost anything can be made using sheet metal forming, including appliances, furniture, structural components, and HVAC systems. In fact, if you take a look around you right now, it's likely you'll come across some product that incorporates sheet metal into its design.
Depending on the type of metal used, the number of processing steps needed to achieve the final form, and the complexity of the design, steel metal forming is also relatively inexpensive compared to similar processes, like forging and metal stamping. Simple designs in standard sizes can be particularly cost-effective.
The relevant tools and equipment needed to form sheet metal will depend on what you want to make. For example, if you need specially shaped holes, cutting with punches and dies would be best. Shearing tools are also useful for cutting off small unwanted slithers in a straight line. Rollers are used to make cone or cylinder-shaped items, and to bend the metal you’ll need something like a press brake.
Let’s talk a little more about sheet metal forming’s various processes as each one is better-suited for making different items.
Before metal sheets get formed, many times the initial flat patterns are laser cut first. Laser cutting uses a high-powered laser to cut shapes into flat metal sheets. It’s one of the most precise methods and can make a plethora of shapes, patterns, and holes. To start laser cutting sheet metal, a blank sheet is attached to the cutter’s bed, and then the laser itself does all the hard work. The machine’s laser beam is controlled by a CNC (computer numerical control) system so that highly accurate and clean cuts can be made. The system can also pre-program different patterns and repeat them again and again.
There is very minimal post-processing needed with this method, and hardly any waste. It is commonly used in automotive, aerospace, and electronics. At Xometry we offer sheet cutting as a standalone service and offer many metals like steel, stainless steel, aluminum, and copper. A potential downside of this method is its high initial cost—the machinery is quite pricey. This is why many customers turn to Xometry for their laser cutting needs. Visit our sheet cutting services page to learn more about what we offer in this area.
One of the most commonly utilized sheet metal forming processes at Xometry is bending. Bending sheet metal requires the use of specialized but fairly simple bending tools, like press brakes. The sheet metal bending process is quick, accurate, and one of the most inexpensive. The process is used to (as the name suggests) make bends and curves on the metal sheet in a straight line. With press brakes, the metal is put or clamped into place and then bent to the required angle.
This sheet metal forming process is often used for vehicle body parts, enclosures, and electrical components. It can be performed on most compatible sheet metal forming materials, like stainless steel, brass, aluminum, and galvanized steel. It does have some limitations, however; the metal needs to have the same thickness throughout, and thicker materials will understandably be much harder to bend.
This process adds a hollow circular roll to the edge of the sheet metal it’s working on to smooth them out, improve safety when handling, and add strength. During curling, the sheets are fed into machines that slowly roll or bend the edges into smooth, rounded shapes. Some curled features require specialized tooling, and machinery might be required for complex shapes or tight rolls.
Depending on their thickness and how ductile they are, most metals can be put through the curling process, including steel, aluminum, and brass. The process is used in HVAC, appliance manufacturing, and architecture for edges on panels, trim, or housings.
Ironing is used to make sheet metal parts smoother and ensure they have an even thickness. This is done by pushing the part through one or more metal-shaping dies that press it, slowly making it thinner and longer without changing its shape too much.
It’s great for products that need the same thickness throughout, like soda cans, and ideal for bendy and stretchy metals like steel and aluminum. The method needs specialized tools and machinery and can’t be used for parts that need drastic shape changes.
This process uses high-pressure fluid to shape sheet metal and can also handle more complex shapes. The blank sheet is held in place over a die, which is in the shape of the final product. The sheet and hydraulic chamber are sealed off, and fluid is pumped directly into the chamber at high speed. As the hydraulic pressure builds up, the fluid presses the metal against the die, forcing it to conform to the shape of the die. It’s suitable for aluminum, stainless steel, brass, and other ductile metals and is commonly used in automotive, medical, and aerospace.
Hydroforming can create shapes with even thickness and very little waste. It’s also one of the more affordable sheet metal forming methods for creating complex pieces in high quantities. Hydroforming equipment, though, is expensive to buy and the forming dies can require a higher upfront investment.
For intricate and hollow cylindrical shapes like cooking pots, beverage cans, and car door panels, many manufacturers turn to deep drawing. The process involves the sheet metal being placed over a die, then pressed with a punch into an open cavity, causing the material to undergo plastic deformation. The process allows for precisely made complex shapes and designs with deeper features.
Materials common in deep drawing include malleable metals like aluminum, copper, brass, and stainless steel. Minimal manual labor is needed with this method, and it’s cost-effective for high-volume production.
Shearing is used to cut sheet metal along a straight line, which is helpful when either cutting the material into smaller pieces or trimming its edges. A shearing machine has two blades that slide past each other, like giant scissors, to cut the metal. A sheet has to be placed on the machine, clamped into place, and then its upper blade is lowered onto the material to make the cut. This is one of the most widely used processes for sheet metal forming, mainly because it’s convenient, quick, produces minimal waste, and reduces costs when making high volumes.
The manufacturing, construction, and auto industries all use it for shearable materials, like steel, aluminum, and stainless steel. The process does sometimes cause the edges to deform or burr, especially when working with thicker materials which some shearing machines might particularly struggle with. For more complex shapes, you’ll have to add in an additional forming process, as this one only does straight-line cuts.
Just like your average paper hole punch, this sheet metal forming method makes holes, slots, or specific shapes by punching the unwanted material out. The metal sheet is held in place against a die, which is in the shape of the final cut-out. A punch is driven down into the sheet metal, pushing it into the die, which shears off the material precisely along the edges of the die, producing the completed cut-out in the material. This automated process is quick, efficient, and ideal for high-volume production of enclosures, brackets, panels, and many other products.
While it can be used with various different metals, some machines might not be able to punch through thicker materials. The more advanced and capable machines are pricey, and you’ll still have to do a bit of post-processing, especially for more complex designs.
There are mainly six sheet metal materials that are used in manufacturing and suitable for sheet metal forming. At Xometry, we offer instant quoting on sheet metal forming for these materials and more.
Stainless steel: This material is super strong, has good malleability, and is corrosion resistant, making it very common in medical, and food and beverage.
Aluminum: Another option with excellent corrosion resistance and malleability is aluminum. This lightweight metal also has thermal and electrical conductivity, and an impressive strength-to-weight ratio. It’s used in everything from household and industrial appliances, aerospace components, and power lines.
Hot-rolled steel: Used in construction and for things like automotive chassis and railroad tracks, hot-rolled steel is a cost-effective material that’s fairly easy to form, although it’s not designed for parts that need extreme precision.
Cold-rolled steel: There are a few more steps to forming this material than hot-rolled steel but this just makes it stronger. It’s used in home appliances, structural components, and aerospace parts.
Galvanized steel: This is a durable and affordable metal with good corrosion resistance. It’s often used in roofing, air conditioning, refrigeration, and industrial machinery.
Copper: This extremely malleable material has good electrical and thermal conductivity which is why it’s so often found in electrical applications.
We often form sheet materials 0.6mm to 6.35mm thick, but depending on the design and the type of metal, we can support other gauges.
Despite the multitude of different processes available, many industries time and time again turn to sheet metal forming for their manufacturing needs. This versatile method is less expensive than some other manufacturing methods, like casting or forging. The process is flexible, allowing for many different designs and applications.
As the metal sheets used are typically very thin, the parts are lightweight with great strength-to-weight ratio. Sheet metal forming offers malleability, precision (both in the forming processes and parts created), and can be formed with lots of different metals, such as the ones we've outlined in the section above. The created parts are strong, durable, weather-resistant, high load-bearing, and long-lasting. Another reason companies love sheet metal forming is because they’re able to produce items in small batches—ideal for rapid prototyping.
Not all sheet metal parts are created equal, and the most important factor in the success of a sheet metal part is the material it’s made from.
The type of metal a sheet metal part is made from must be chosen carefully to ensure that the part meets fabrication requirements during manufacture and performance requirements in its final application. Picking the wrong material can cause part or whole product failure, low yields, high costs, poor performance or a number of safety issues.
Imagine a safety critical structural part failing due to improper material selection, and you have an idea of one potential concern. If you imagine products having to be recalled, at a high cost, due to in-use failure you have an idea of another potential concern.
The process of selecting the material for a sheet metal part can be complex because of the sheer number of factors involved. The issue is something that requires careful consideration.
The most important questions to answer when selecting a material for sheet metal parts are:
Fig. 1: Sheet Metal Parts at Komacut
In this guide, we'll look at the most common sheet metal materials used and go over the factors that need to be considered when choosing the right material.
There are many types of sheet metal, and each type has its benefits and drawbacks that must be considered when selecting a material for a project. The different properties different materials have make them suitable for different applications.
We will explore the types of sheet metal materials used at Komaspec and give examples of real-life uses for each of them.
Mild or Low Carbon Steel
Mild steel is by far the most commonly used material for sheet metal fabrication. The relative strength it has, combined with the ease of fabrication and relatively low cost compared to stainless steel or aluminum, means that it’s suitable in plenty of applications. These steels can be used to create a wide variety of custom steel parts. Automotive body panels, furniture and structural parts are common examples of mild steel in application.
Mild Steel Pros
Mild Steel Cons
Stainless Steel
Stainless steel is an alloy containing chromium, which provides good corrosion resistance and improved strength. Stainless steel is great in outdoor applications or other applications in which parts might be exposed to rust or corrosive chemicals. It’s also useful in applications that need more hardness than mild steel. As well as this, it is non-magnetic and non-sparking, making it ideal for medical instruments.
Fig. 2: Mill Finish – Stainless Steel
Stainless Steel Pros
Stainless Steel Cons
Galvanized Steel
When steel is galvanized, a layer of zinc is bonded to its surface. This method serves as a cost-effective way to build a high level of corrosion resistance into the material. In turn, this reduces the potential for rusting prior to fabrication and the need for additional surface finishing. Galvanized steel is perfect for things like fencing and other outdoor frameworks that are exposed to the weather.
Fig. 3: Cold Galvanized Steel
Galvanized Steel Pros
Galvanized Steel Cons
Aluminum
Aluminum has many wonderful qualities. Its primary qualities are its high level of resistance to rust and its reduced weight, being one-third of the weight of steel. It is less strong than other materials, but this can sometimes be overcome through design. In some applications, aluminum can also be designed to be equally as strong as steel.
Because of its lack of strength, aluminum may often not be able to handle the same stresses as steel. As such, you might want to contact our representatives at Komaspec to help you decide if aluminum is suitable for your intended use or not.
Fig. 4: Aluminum RAL
Aluminum Pros
Aluminum Cons
Spring Steel
Spring steel is a very resilient material containing manganese and high concentrations of carbon. It is designed to bend or flex under load and to return to its original shape when the load is removed. This makes it an excellent choice for making latching mechanisms, drive belts and, of course, springs.
Spring Steel Pros
Spring Steel Cons
For more info about each of the sheet metal materials Komaspec offers, including specific physical properties and surface finishing options, you can refer to the sheet metal material selection on our website.
Order and track sheet metal components online through Komaspec's on-demand sheet metal fabrication platform.
Visit Komacut.com
The costs that come with sheet metal parts fabrication begin with the cost of the raw material. Costlier materials, such as aluminum, stainless steel, and copper, can provide superior performance compared to cheaper materials, such as mild steel and galvanized steel. Still, they obviously come with a higher price tag.
In some cases, a cheaper metal will be suitable for a job and will provide adequate performance at a lower cost. For example, if aluminum is too expensive for a part that requires light weight and corrosion resistance, galvanized steel might be a better choice.
Ultimately, choosing the right material will mean weighing up performance requirements and the cost constraints of a project.
The table below shows a rough outline of how much each material costs. We can see that, while aluminum is twice as expensive as steel per kg, stainless steel is nearly five times more costly. Titanium is much more expensive again and is used sparingly in products such as jet engines, where the extra strength it provides is crucial.
Fig. 5: Material Cost Per Kg (USD)
The Difficulty in Comparing Material Costs
If you want to learn more, please visit our website applications of custom sheet metal enclosures.
When considering which sheet metal material to buy for a project based on cost, there’s more to consider than just the price of a material per kg. You have to weigh material cost per kg against the design and performance goals of the project. Not all sheet metal is created equal in strength, weight, and appearance.
Stainless steel is stronger by weight than aluminum, for example, meaning that designs can be adapted. Thinner stainless steel can be used for a tank or vessel than it can for an aluminum one, for example.
Cost Increase of Custom Steel Parts
Custom design requirements often impact the price of steel sheet metal parts. This is because custom designs often require more intricate processes and skills to manufacture, increasing the cost of labor and materials.
Custom metal parts fabrication often also requires additional processes, such as welding, cutting, and bending, which can also increase the cost of the parts. They may require the use of specialized tools and equipment to construct correctly as well.
Understanding the mechanical properties different sheet metals have and the effect these properties have in application is critical to selecting the right material. There are many physical qualities inherent in different metals, and each one can be used to serve a different purpose.
Some of the most essential mechanical factors to consider in the material selection process include:
Strength of Sheet Metal Parts
Material strength is often the most widely used metric in determining material suitability. It is measured according to how much load a material can withstand before it bends out of its original shape. This bending is also known as plastic deformation.
There are two ways of looking at the strength of a material when it comes to choosing one for manufacture. Considering each separately may give a different outcome in decision making.
Strength By Cost
This simply considers how strong a material is in respect to how much it costs. Titanium is an example of a material with a high cost to strength ratio, and mild steel is an example of the opposite.
For metal enclosures or tanks that require large amounts of high strength material at low cost, for example, low-carbon (mild) steel would generally be considered the ideal material.
Strength By Weight
This considers how strong a material is in relation to its mass (or weight). Gaining high strength with lightweight materials is important in certain applications. In airplanes, for example, reducing weight is essential, and aluminum is often a good choice.
Strength to weight properties are also assessed by looking at specific strength.
Interestingly, in a comparison of aluminum, carbon steel, and stainless steel, the aluminum alloy has the highest specific strength (ASM Material Data Sheet), despite having the lowest tensile strength.
Fig. 6: Tensile Strength vs. Specific Strength
Also referred to as formability, this is the ability of a material to be stretched without cracking or breaking. If a material is highly ductile, it will withstand a large amount of stretching. Stretching commonly occurs in manufacture when a tight radius is formed during a metal stamping or folding process.
Fig. 7: Sheet Metal Materials at Komaspec
A simple way to visualize ductility is to imagine a material acting as a spring - the greater the elasticity of a material, the better its ductility. One thing to note is that this flexibility can be increased using a metal-forming process called annealing.
Corrosion Resistance
Corrosion occurs when a metal deteriorates as a result of the action of air, moisture or a chemical. The most common form is rust, which happens when iron in a material reacts with the oxygen and moisture in its surroundings. Good corrosion resistance (Metals - Corrosion Resistance to Aggressive Fluids) is a crucial factor in sheet metal selection because corrosion can weaken steel in a surprisingly short period of time if the conditions are right.
Fig. 8: Corrosion From Aggressive Fluids
The two main factors that help reduce corrosion are:
What is the Best Material for Corrosion Resistance?
Stainless Steel
Stainless steel contains chromium, which forms a thin film of chromium oxide on its surface, protecting it from corrosion. Stainless steel can become discolored, or it can rust if there is long term exposure to the elements. It is particularly vulnerable to corrosion where there are high salt concentrations. However, the resistance is greatly superior to mild steels.
Bimetal corrosion is a risk with stainless steel and must be considered when mating with other parts or fasteners.
Aluminum
A lightweight alternative to steel, aluminum is a naturally non-reactive metal that will not corrode in the presence of air or water.
Aluminum can be somewhat vulnerable to corrosion when in contact with concrete, however, and there’s also a risk of bimetal corrosion. Both of these problems can be overcome through anodizing or painting.
Modified Mild Steel
Using galvanized mild steel could be a great alternative if cost is a factor. The Zinc coating gives a layer of protection at lower cost. Be aware, however, that when galvanized mild steel sheets are cut, the edges are exposed and will be vulnerable to rust.
Mild Steels
Mild carbon steels without secondary finishing will rust rapidly in the presence of moisture or salt. In fact, unprotected steel sheets can begin to rust even before fabrication, which often leads to the need for deburring or chemical treatment to remove rust before surface finishing.
Rust can be so severe, in some cases, that it impacts the final part appearance even after painting. Parts can appear “mottled” or like they have a blotched surface when this happens.
Sheet metal part fabrication processes involve procedures such as cutting, bending, and joining sheets of metal. These procedures create different configurations of sheet metal to create custom steel parts. Each material has its own specific advantages and disadvantages in the fabrication process that need to be considered.
Laser Cutting
Laser cutting is a precise and reliable method for cutting all different types of metal. This method is a great option in many different situations. However, it’s particularly useful where speed and precision are important, such as in the automotive industry. Lasers are also useful for cutting thicker materials, for making complex cut-outs and for making very clean cuts.
Shiny metals, such as aluminum and copper, are more difficult to cut, although it is still possible to cut these materials with a laser. The minimum / maximum thickness which can be cut, however, varies depending on the material type, which in the case of very thick or very thin material, may limit potential choices.
Bending
There are two factors that have an impact on bendability:
Some materials can be bended more easily than others and with more success in application. It’s worth noting, however, that even within the same material, there can be differences in bendability between different grades. If ductility is important, for example, the series aluminum is best avoided as the hardness of the material can result in micro-cracks and part failure duing bending.
Generally speaking, aluminum is commonly considered a good choice where sheet metal bending is required.
Designs with tight bend radii and low tolerances will mean that a more bendable material is required. For more about bend design, read our article on sheet metal design guidelines. Very stiff materials (i.e. medium carbon or stainless steels) may require larger reliefs are larger bend radii vs mild steels and aluminum parts.
Fig. 9: Metal Bending at Komacut
Weldability
Welding is one of the most common methods for joining and manufacturing metal components. This process uses a high-powered and highly controlled electric arc to heat base metals to the point where they melt. They are then joined and solidify as almost one piece.
The weldability of sheet metal will depend on the type of filler metal used, the process used and the material makeup of the sheet.
Mild carbon steels are highly weldable with a variety of processes, are generally finished with secondary processes which help to resolve discoloration of the base material. Aluminum requires TIG welding, which can be more time and cost intensive than MIG, and the material is more vulnerable to deformation and discoloration due to heating during the welding process. Stainless is also weldable, but requires TIG or special robotic welding equipment and may need passivation or secondary processes to hide discoloration from the welding process.
Fig. 10: Robotic Welding at Komacut
Different materials have different properties when it comes to surface finishing. Not all materials are compatible with all surface finishing options, such as anodization being largely specific to aluminum, or the difficulty of electropolishing mild steel parts.
For which options are available for various sheet metal materials, please see the table below or explore in greater detail in our surface finishing article.
Finish Corrosion Resistance Coating Thickness Abrasion ResistanceTable 1: Surface Finishing: Corrosion, Thickness, Abrasion
Finish Carbon Steel Stainless steel Aluminium Application Visual Requirements Thickness Corrosion resistance Mill Finish Internal Parts or Parts with Subsequent Processing Low-Visual - - Antirust Oiling Parts with Subsequent Processing Low-Visual - 24 Hours NSS Brushed Indoor Med-Visual - - Anodized Indoor / Outdoor High-Visual - - Mircro-Polishing Indoor / Outdoor High-Visual - - Passivation Indoor / Outdoor Med-Visual 0.5 to 15μm - Zinc Plating Indoor / Outdoor Low-Visual 5 to 25μm 48 to 94 Hours NSS E-Coating Indoor / Outdoor Low-Visual 5 to 25μm 96 Hours NSS Powder Coating Indoor / Outdoor High-Visual 70 to 150μm 480- HoursTable 2: Metal Finishing Guide
The application of the part often determines the finishing requirements. Some reasons for wanting an enhanced surface finish include:
Because these aspects are critical to quality for many applications, it’s important to think about these requirements when selecting a material.
Aesthetics
Polishing is a common technique used to create a high-quality look that’s pleasing to the eye. The process involves progressively removing all surface imperfections to give a metal part a shiny finish.
Fig. 11: Surface Finishing
Polishing for Sheet Metal Parts
Stainless steel can be brought to a mirror finish and is very durable; aluminum is less durable and can take longer to reach the same finish. It is not possible to create a durable polished surface on mild steel.
Hygienic Sheet Metal Parts
Sheet metal parts are often used in both the food industry and medical settings. The material chosen must be resistant to the build-up of bacteria and other contaminants.
Stainless steel, for example, is a popular choice for sheet metal products because it is non-porous and resistant to corrosion. This eliminates the need for potentially toxic paints and other coatings.
Additionally, stainless steel can be easily cleaned and sterilized using various chemical and thermal methods. This makes it an ideal choice for food-grade products and medical instrumentation.
Stainless steel 316, for example, is widely used for food service or medical equipment due to its excellent resistance to chemical cleaning agents, acids and other corrosion.
Durability for Sheet Metal Parts
Durability is the main factor that affects a material’s resilience to dents, scratches and bending. Also important in hygienic environments, the durability of a material affects how well it can withstand harsh environments without needing to be repaired or replaced.
Stainless steel is a great option if a part needs to resist scratching and be easy to repair. When scratched, it does not cause possible contamination with aluminum oxide. Aluminum, along with copper, will resist scratches and deformation very poorly.
Mild steel is another durable material, but the paints and coating needed should be considered as they can often lead to the same problems with contamination.
Material finishing requirements will help determine the best material choice for any particular part. For more about different types of finishing, read this guide.