How To Reduce Sheet Metal Fabrication Costs

Sheet metal fabrication is a manufacturing process that involves cutting, bending, and joining metal sheets to form various geometries. This manufacturing process is widely used for its versatility and ability to produce highly functional, durable parts. As with other manufacturing processes, cost is a crucial consideration in sheet metal fabrication.

Sheet metal fabrication cost depends on several factors, from the design stage to postprocessing, and can vary significantly. This article explores strategies by which you can reduce the cost of sheet metal parts by optimising various aspects of the fabrication process.

Factors That Affect Sheet Metal Fabrication Cost

Before delving into how to reduce sheet metal fabrication costs, it is imperative to understand the factors affecting these costs. These factors, which cut across different aspects of sheet metal fabrication, include the following:

Part design and geometry

Part complexity is a leading factor that impacts cost in several ways. More complex parts typically require specialised tooling, longer processing times, and more skilled labour. Part geometry also dictates the fabrication processes used, and these processes vary in cost.

Material

Materials significantly affect the cost of a sheet metal fabrication project. For example, a stainless sheet costs three times as much as a mild steel sheet of the same size. A 2 mm thick, 1 m² mild steel sheet costs approximately £42.50, while its stainless steel counterpart costs £130.

Similarly, material cost varies by thickness. A 2 mm thick,1 m² aluminium sheet costs $45, while a 3 mm thick sheet of the same size costs £70. Material thickness also affects cost by impacting fabrication efforts. Thicker materials require more time and effort to cut, bend, or weld.

Specified tolerance

Tolerance impacts sheet metal fabrication costs in different ways, one of which is the processes used. Fabricators can achieve loose tolerances with less expensive cutting methods like flame cutting. On the other hand, more accurate but costlier cutting methods, such as laser cutting, are required to achieve tight tolerances.

Tolerance also impacts sheet metal fabrication costs through machining efforts. To achieve tight tolerances, highly skilled fabricators must take great care throughout manufacturing, often needing to repeatedly stop and measure the workpiece.

Finishing and post-processing

Finishing and post-processing incur additional, albeit often necessary, costs. 

Production volume

Economies of scale apply to sheet metal fabrication costs. Larger production volumes cost less per unit, as processes are replicated and tooling can be reused.

Reducing Sheet Metal Cost

The following are some of the most effective strategies to reduce the cost of sheet metal parts.

Optimise design

You can optimise your sheet metal design in several ways to reduce the cost of sheet metal fabrication.

• Use standard specifications: Design radiuses, corners, and bends with standard dimensions obtainable from bending charts. Similarly, use standard hole sizes in your design, as fabricators can easily drill these using available drill bit sizes. Custom specifications may require additional tooling and processing time to achieve. Standardisations make processes more straightforward and less time-consuming for fabricators, significantly reducing sheet metal fabrication costs.
• Minimise aesthetic features: Certain sheet metal projects, such as decorative panels and barriers, have aesthetics as the primary objective, so this consideration does not apply. However, for primarily functional sheet metal parts, limit the use of aesthetic features such as decorative cut patterns and aesthetic embossments, as these increase fabrication time and effort.
• Limit the use of tolerances: Only apply tolerances when they affect part functionality or are necessary for assembly.

Choose the right material.

Material selection significantly impacts sheet metal fabrication costs in various ways. 

• Select cost-effective material options: Application and environmental requirements are the primary considerations when selecting a material. However, certain applications have cheaper material alternatives that meet all requirements. For example, while stainless steel with corrosion resistance properties is a suitable material for a sheet metal electrical enclosure, its properties and cost are unnecessary in this application. Mild steel is a more cost-effective but perfectly suitable alternative. Perform proper material selection to choose cost-effective materials that still meet the functional requirements of your application.
• Specify required thickness: Use testing and simulation software to determine the necessary thickness for your specific application. This process, particularly important for stress-bearing applications, ensures you don’t specify more thickness than is needed for your application.
• Material availability: Select readily available materials to reduce sheet metal fabrication costs related to material scarcity. Certain materials, such as aluminium, steel, and stainless steel, are more readily available than others, such as titanium, and their prices reflect their availabilities. Conduct thorough material selection to ensure you choose cost-effective, readily available metal with all the required properties of your application.

Optimise cutting layouts and patterns (Nesting)

Nesting is the process of arranging cut layouts on a sheet of metal to optimise placement and minimise wastage. Use CAD software to carry out nesting for sheet metal parts that need portions cut out of a larger sheet. Calculate the area of your cutouts to ensure they correspond with the area of your base sheet. Using models and drawings of the cutouts and the sheet, position the cutouts on the base sheet, adjusting the placement and orientation to maximise the use of material and minimise wastage.

Minimise part count

Minimise part count to avoid unnecessary joining processes. Unless the part geometry is too complex to produce without joining components, it is best to consolidate your design into a single part. Part consolidation reduces sheet metal fabrication costs by minimising the need for assembly and reducing processing time. Aim to design geometries that fabricators can create with as little cutting and joining as possible. The image below shows a part formed by cutting and bending a single sheet compared to joining multiple components.

Follow sheet metal design for manufacturing guidelines

Apply sheet metal DFM guidelines during the design stage to ensure seamless, high-quality, cost-effective fabrication. Many of these guidelines aim to reduce processing time and minimise wastage, significantly reducing production costs and overall sheet metal fabrication costs. See our sheet metal design article to learn everything you need to know about optimising your design to ensure cost-effective manufacturing.

Incorporate off-the-shelf components

Use readymade off-the-shelf components in your parts, where applicable. Rather than fabricate existing components from scratch, simply procure and incorporate them into your part at a fraction of the cost. This saves significant processing time and cost.

Specify relevant finishes

There are various surface finishes available for sheet metal parts. These finishes vary in benefits and cost. Only specify finishes required by your application to minimise sheet metal fabrication cost. Similarly, select cost-effective alternatives that meet your requirements. The table below compares the cost and benefits of some common sheet metal finishes. See our sheet metal finishes gallery for all available options.

Sheet metal fabrication finishes and their costs

Conclusion

Reducing sheet metal fabrication costs involves a combination of design optimization, careful material selection, and efficient manufacturing techniques. By standardising design elements, minimising unnecessary features, and choosing cost-effective materials, you can ensure your project is cost-effective without sacrificing quality.

Why Choose Geomiq?

Geomiq offers precise control over sheet metal fabrication costs via our instant quoting platform. To get started with our sheet metal services, head to our instant quoting platform and upload your design. Our innovative platform provides options on materials, thickness, and finishing, providing instant to 24-hour quotes based on your preferences.

With a few clicks, you can receive your finished part in as little as three days. Not sure which options are best for your project? Our expert designers and engineers are available to guide you on design, process selection, and custom solutions to ensure seamless, cost-effective manufacturing for your project.