Sheet metal fabrication plays an important role in industries such as automotive, electronics, EV infrastructure, and industrial equipment. Techniques like stamping aluminium, sheet bending, and metal pressing enable the production of a wide range of parts. However, these processes also present challenges that can affect precision, lead times, and costs.
Managing these factors is essential for achieving precise, cost-effective results. This guide highlights the most common fabrication challenges and the best ways to overcome them.
1. Sheet Splitting
Splitting occurs when sheet metal is stretched beyond its limit during the forming process. This is most common in areas with deep shapes, sharp corners, or complex designs, where the metal becomes too thin and weak.
How to Solve It:
- Optimise Material Selection: Use metals with higher formability or softer grades that can handle deeper draws without tearing.
- Simulate Forming Early: Conduct forming analysis during the design phase to identify and correct high-stress areas.
2. Springback
After metal sheet bending, the material often springs back slightly due to its natural elasticity, causing deviations in angles and dimensions. This is common with high-tensile materials such as stainless steel and aluminium alloys, which resist stretching.
How to Solve It:
- Adjust Bend Allowance: Factor in material thickness and elasticity when calculating bend angles to compensate for springback.
- Use Precision Press Brakes: Employ machines with accurate force control for consistent bending results.
3. Hole Deformation
Holes can distort during bending or forming, especially near bends or in thin sheets, leading to poor fit and alignment. Cracking and surface flaws may occur when bend radii are too tight or tooling is incorrect.
How to Solve It:
- Relocate or Resize Holes: Position holes away from bend lines or increase clearance in the design stage.
- Use Reinforcement or Pre-Forming: Add strengthening features or form holes after bending to maintain their shape.
4. Burrs and Inaccurate Cuts
Poor cutting or sheet metal stamping techniques can create burrs and rough edges, compromising fit and function. This issue is common in high-precision components such as electronics housings, EV enclosures and other tight-tolerance parts.
How to Solve It:
- Use Precision Cutting and Correct Settings: Opt for laser cutting or CNC punching with sharp tools, and adjust cutting speed, pressure, and tool type based on material thickness and hardness for clean, accurate edges.
- Apply Finishing and Inspection: Remove burrs through deburring methods such as grinding or brushing, and perform dimensional checks to verify accuracy before the next process.
5. CNC Programming Errors
Incorrect CNC parameters or tool paths during CNC machining or sheet metal cutting can lead to wrong dimensions, wasted material, or even part failure.
How to Solve It:
- Double-Check Tool Paths: Validate CNC programs through simulation before actual machining.
- Standardise Programming Procedures: Use proven templates and verification steps to reduce human error.
6. Fit and Assembly Problems
Metal parts that appear correct in CAD may not fit together properly after fabrication. This is often due to small deviations across multiple steps or variations in forming, especially when tight tolerances are required.
How to Solve It:
- Validate Fit with Prototypes: Test-fit parts early in the process to identify alignment issues before full production.
- Use Fixtures and Jigs: Apply assembly guides during welding or joining to maintain accuracy and consistency.
Expert Solutions for Precision Sheet Metal Parts
Sheet metal fabrication can be complex, but ARRK turns challenges into precision. Backed by decades of expertise in metal sheet prototypes and low-volume production parts. We combine expert problem-solving with proven techniques to ensure exceptional quality and performance.
Ready to simplify your next sheet metal project? Get in touch with our team today!
