Wet Paint vs. Powder Coatings
Leave a CommentSince 1992, Metal Works of High Point has provided durable powder coating services for various industries and applications. To help our customers better understand the difference between powder coat vs. paint, we will focus on the suitability, benefits, and cost-effectiveness of these processes for industrial use.
Wet Paint vs. Powder Coatings
There are several factors to consider when choosing between wet paint and powder coatings. We cover some of the top considerations below.
What Is Wet Paint?
Wet paint is easy to apply and is the most affordable coating option available. In this process, a pressure sprayer applies a liquid solvent containing suspended color particles to a dry metal surface.
Both powder coating and the wet paint process can cover an entire surface. However, with wet painting, the painted metal does not need to be heated for curing. As the metal dries, the solvent evaporates. While the drying process is considerably longer with wet paint, it does not require any heating equipment.
Process
This versatile process is used to adhere liquid paint to a metal surface. Unlike wall painting, wet paint in an industrial setting utilizes a pump, spray, or pressurized vessel to achieve an even coating. Several paint layers may be needed, resulting in more time and labor costs compared to powder coating.
Benefits
- Easy Color Matching. Wet paint offers superior color-matching capabilities, making precise touchups easier.
- More Color Options. Mixing wet paint creates more color options than the limited pigments available for powder coatings.
- Self-Drying Products. Wet paint can dry without needing additional equipment, which is ideal for finishing products that cannot withstand heat treatments.
- Ideal Coating Thickness. Unlike powder coatings, wet paint can be applied in thin layers, accommodating metal pieces that must fit together.
- Greater Accessibility. Wet painting is more accessible than powder coating, as it does not require high-tech, expensive equipment to achieve desired results.
What Is Powder Coating?
Powder coating is made of finely ground particles of colored acrylics, polyurethane, or polyesters. The material is given a positive charge and dry-sprayed directly onto metal products that have received a negative charge. The process results in statically charged colored particles that cling to the negatively charged metal.
Once a metal product receives a uniform coat of the desired thickness, it is rapidly heated to cure and melt the powder to the metal. This curing and heating process typically takes about 10 minutes, depending on product size.
Process
Powder coating requires the application of a dry, free-floating organic powder via electrostatic attraction. To ensure an even coating, the piece must first be thoroughly cleaned.
The powder can consist of the following materials:
- Acrylic
- Epoxy
- Polyester
- Polyester-Epoxy
- Polyurethane
Benefits
- Color Retention. Powder coating allows the colors to stay truer longer than wet paint.
- Durability. Once set, powder is stronger than wet paint and can resist corrosion, rust, and damage, offering a more uniform coating that lasts.
- Low Maintenance. Powder coating only requires routine washing with soap and water, eliminating the need for harsh chemicals.
- Variety of Texture Materials. Powder provides more texture options than other coatings and is ideal for steps, ramps, and other metal products.
- Coating Consistency. The process ensures even, smooth finishes without application marks.
- Efficiency. Since powder particles are easily attracted to the metal surface, very little powder gets lost to over-spraying, making powder coating more efficient than wet paint. The process only requires one quick application with minimal drying time.
- Environmentally Friendly. Powder that falls to the ground can be reused, significantly reducing waste. The particles do not contain volatile organic compounds often found in paints, making the coating a more sustainable option.
Quality Coating Services by Metal Works
Metal Works of High Point Inc. offers reliable powder coating services that promote high-quality protective and decorative finishes in precision components. Contact us for more details about our manufacturing capabilities and learn how our services can meet the demands of your specific application.
Technical Comparison: Manual vs. Robotic Metal Welding
Leave a CommentMetal Works of High Point has a long-standing reputation for delivering top-quality metal fabrication services. We offer manual and robotic welding solutions tailored to meet diverse project needs.
Today, we’re taking a closer look at manual and robotic welding techniques. We’ll compare precision, costs, speed, and flexibility to help you determine the best welding method for your next project.
Precision
Manual Welding
Skilled welders bring a level of precision that is hard to match. Their expertise allows them to adapt to intricate joint shapes, varying weld thicknesses, and more challenging positions. This is particularly useful when working with complex or tight welds requiring real-time adjustments.
Robotic Welding
Robotic metal welding technology offers unmatched consistency and repeatability. Once programmed, they follow a precise path to produce identical welds every time.
Robots can operate tirelessly, delivering greater output while maintaining high-quality standards around the clock. This level of precision is ideal for high-volume production where uniformity is essential.
Costs
Manual Welding
The initial equipment cost for manual welding is relatively low. Still, labor costs can increase, especially for large projects or repetitive tasks requiring skilled welders. Ongoing expenses for maintenance and training are also necessary to ensure welders remain proficient with the latest techniques and safety standards.
Robotic Welding
Automation in fabrication can come with a high upfront cost, including the price of the robots and programming. However, the long-term cost savings are significant due to increased efficiency and reduced labor costs, as one operator can oversee multiple robots.
Precise welds also reduce material waste, leading to further savings over time.
Speed and Flexibility
Manual Welding
Manual welders require setup time and torch maneuvering. Fatigue can also impact their performance, increasing the chance of variation in weld quality and speed. Production speed ultimately depends on the welder’s skill level and the complexity of the task.
Manual welding consistently offers superior flexibility, allowing welders to adapt to different materials and specifications.
Robotic Welding
Robots excel in high-rate production environments, performing repetitive tasks at consistent speeds without slowing. This makes them ideal for projects requiring a high volume of uniform welds.
Still, robotic systems are less flexible overall than manual welders. They are best suited for tasks that demand consistency and repeatability over projects requiring frequent adjustments or custom welds.
Whether you’re looking for repeatability, flexibility, or speed, there’s a welding method for your project. Understanding the strengths and limitations of manual and robotic welding will allow you to make an informed decision that aligns with your project requirements and budget.
Welding Services From Metal Works of High Point
At Metal Works of High Point, we offer both manual and robotic welding services to cater to our clients’ unique needs. Whether you need skilled welders’ adaptability or robotic systems’ precision and efficiency, we have the expertise and technology to deliver exceptional results.
Request a quote to learn more about our welding services. Trust Metal Works of High Point to provide the high-quality welding solutions you need.
How to Choose the Right Metal Fabrication Provider
Leave a CommentChoosing the best metal fabrication provider can be a challenging task; however, making the right selection is critical to the success and quality of your project. To ensure you find a metal fabrication provider that can effectively meet your needs, there are various important factors to consider. These range from their level of experience to the types of equipment used, certifications, customer service, and more.
Here, we’ll go over the key considerations to keep in mind when determining the right metal fabrication partner and why you can trust Metal Works of High Point for all your sheet metal fabrication needs.
Considerations for Choosing the Right Metal Fabrication Provider
When narrowing down your search for the right metal fabrication provider, it’s important to consider the following:
Track Record & Experience Level
Be sure to look into a potential provider’s history and level of experience. Newer companies may not have much experience working on your type of project, so look for a provider with a proven track record for meeting similar needs as yours. You’re more likely to get higher-quality service at a better price if you select a metal fabrication partner with a long history of successful projects.
At Metal Works of High Point, we’ve been providing turnkey contract metal fabrication services since 1992. Our decades of experience allow us to deliver quality metal fabrication solutions that align with our customers’ unique needs, no matter how complex. View a small sampling of our previous work here.
Equipment Selection
A provider’s metal fabrication equipment will often determine the efficiency and quality of your project. For this reason, choose a provider that has invested in the latest equipment and stays up-to-date with the industry’s technological advancements. Metal Works of High Point is committed to innovation and uses state-of-the-art equipment and software to ensure precise, high-quality fabricated products.
Customer Service
Customer service is crucial when it comes to building a long-term relationship with your metal fabrication partner. Be sure to talk with prospective providers about common issues they’ve encountered in the past and how they were resolved. The right partner will provide responsive communication throughout the duration of your project and be transparent when it comes to pricing and timelines.
Metal Works of High Point takes a personalized approach to every project. With a focus on respect, honesty, and top-notch customer service, we can deliver the metal fabrication solutions you need while maintaining open, responsive communication.
Workforce Size & Expertise
It’s important to consider the size and expertise of a fabricator’s workforce. Companies with smaller teams may have a difficult time completing your project on time. It is also critical to ensure your fabricator’s team is composed of highly skilled and qualified craftsmen who can deliver high-quality work.
At Metal Works of High Point, our expert team brings hundreds of years of combined experience to every project. In addition to investing in the latest technology, we also invest in the training and education that goes with it to guarantee we’re providing the best possible solutions.
Certifications & Adherence to Quality Standards
Choose a metal fabrication provider that holds relevant certifications and adheres to high standards for quality. A company that values quality will be more equipped to deliver fabricated parts that meet or exceed expectations. Metal Works of High Point is ISO 9001:2015 certified, and we hold ourselves to the highest quality standards to ensure we provide superior products. In addition to our ISO certification, all of our welders are D1.3 certified.
In-House Finishing Capabilities
Look for a company that goes beyond initial construction by offering a range of finishing capabilities. Choosing a fabricator that can handle your project from start to finish saves time and money while ensuring consistency throughout the entire process.
At Metal Works of High Point, our capabilities extend to in-house powder coating and metal finishing services. This allows us to deliver completely finished products that meet your decorative and protective requirements.
Choose Metal Works of High Point—We Check Every Box
Metal Works of High Point has extensive experience providing top-quality metal fabrication services, including laser cutting, CNC forming, CNC machining, and welding. We also offer in-house powder coating and a range of other finishing services to protect your fabricated components.
From our ISO 9001:2015-certified facility, we can deliver the sheet metal fabrication solutions you need while meeting rigorous quality standards. For more information about our specific capabilities, or to work with us on your next project, contact us or request a quote today.
Advantages of In-House Powder Coating in OEM Metal Parts
Leave a CommentAt Metal Works of High Point, Inc., we pride ourselves on being a premier manufacturer of custom-fabricated metal components and assemblies. We offer a range of manufacturing capabilities and fine-tune our powder coating and finishing services to meet the evolving needs of our customers.
This article explores the benefits of powder coating and its growing impact on quality control, cost savings, and overall efficiency.
What is In-House Powder Coating?
Powder coating involves applying dry paint to a surface. Unlike traditional wet paint applications, powder coating involves spraying a solid powder coating directly onto the base material to create a hard, highly protective layer. This reliable, cost-effective method is widely used in different industries.
The powder used in this process is made from finely ground pigments and resin that are electrostatically charged and then sprayed onto the grounded metal parts. The charged powder particles cling to the metal surface, allowing for even coverage with minimal waste.
The parts are then cured in an oven to melt the powder into a smooth, aesthetically pleasing finish. This process is environmentally friendly, producing fewer volatile organic compounds (VOCs) than traditional liquid coatings.
Advantages of In-House Powder Coating in OEM Metal Parts
Cost Savings
Keeping powder coating services in-house allows for more accurate project quoting, eliminating unexpected expenses and additional markups. We work to fully understand project requirements and realize cost-effective in-house powder coating solutions that meet your specific needs.
We intentionally reduce our dependence on third-party schedules, mitigating the potential delays and additional costs associated with outsourcing. We then pass these cost savings on to our customers.
Quality Control
Outsourcing powder coating can compromise quality control, especially with metal finishing projects. Offsite processes often result in surface imperfections and uneven paint coverage, particularly with gloss finishes.
Our in-house powder coating specialists can identify and address these issues before painting. This close supervision prevents problems like color mismatches and non-uniform thickness, resulting in a high-quality finish.
Having an in-house team also allows for continuous improvement and fine-tuning of the process, ensuring that the highest standards are consistently met and client needs are met.
Reduction of Waste & Rework
Offsite powder coating often leads to overlooked imperfections, only discovered after returning to the fabricator, increasing lead time and costs. Shipping metal parts to and from an offsite vendor can cause damage, further adding to waste and rework.
Specialists at our metal fabrication facility can quickly detect and correct defects before painting, reducing waste and rework and maintaining the integrity of the parts used in the fabrication process. Our streamlined approach reduces material wastage and minimizes environmental impact for more sustainable manufacturing practices.
Speed & Efficiency
Outsourcing powder coating extends lead times and can delay product delivery by days or even weeks. With in-house powder coating, the fabrication process can be completed in as little as a day depending on order size.
Outsourcing powder coatings also creates fluctuations in lead times. When you choose in-house powder coating, you can count on us to deliver finished products faster than the competition.
Customer Service & Satisfaction
In-house powder coating allows fabrication teams to oversee the entire project from start to finish. This direct management results in higher-quality manufacturing outcomes.
Investing in in-house powder coating is a significant value-add for fabricators committed to offering clients better service and superior products. This approach guarantees that any issues are promptly communicated and addressed. Customer feedback is directly integrated into the process, fostering a collaborative and responsive service environment.
Conclusion
In-house powder coating offers numerous advantages, including cost savings, improved quality control, reduced waste and rework, and faster turnaround times. At Metal Works of High Point, we’re equipped to handle all your custom finishing needs, including high-quality decorative or protective finishes fabricated to your exact specifications.
For more information about our custom finishing capabilities, contact us. You can also request a quote based on your project’s requirements.
Mastering the Craft: A 30+ Year Journey Through the World of Metal Works
Leave a CommentMetal fabrication is a manufacturing process in which raw metal materials are transformed into final products through various techniques. It requires skilled craftsmanship and advanced technologies to create multiple metal structures, components, and products.
Metal Works of High Point boasts over 30 years of experience in this dynamic field! We are a second-generation family-owned and operated business offering turnkey contract metal fabrication solutions catering to many industries. Our expert team proudly delivers American quality components and craftsmanship locally, nationally, and internationally.
What We Offer
Our state-of-the-art facility, coupled with our highly skilled members, enables us to deliver a comprehensive suite of services:
Laser Cutting
Metal Works of High Point utilizes advanced 3-axis laser cutting systems for precise and intricate metal designs. Automated sheet loading and a 24-hour operational system ensure exceptional accuracy in fulfilling your custom laser-cutting needs.
CNC Forming
Our CNC forming services utilize state-of-the-art automatic panel bending technology to efficiently produce intricate workpieces and large-scale bends. We also have CNC press brakes featuring movement capabilities along five axes and press capacities up to 170 tons. This allows us to create precision parts with tolerances of ±0.010 inches made from various metals.
CNC Machining
We utilize advanced CNC machines for milling, lathing, and tooling to fulfill high-volume orders with precision. Our in-house services offer complete product creation and management, ensuring a seamless process from concept to final product.
Welding
At Metal Works of High Point, we offer various industrial welding services, including robotic, spot, tungsten inert gas (TIG), and metal inert gas (MIG) welding. Our professional welders use advanced technologies and 3D software to ensure the structural integrity of metal components.
Finishing
Our experts excel in providing durable powder coating services. Thus, clients can rely on us for high-quality decorative and protective finishes for precision components. In addition, we collaborate with local suppliers to offer a range of finishing services, including plating, oxidizing, and polishing.
Industries We Serve
Metal Works of High Point offers tailored solutions to various industries, including:
- Appliances: fasteners, hardware, and components for refrigerators, washing machines, air conditioners, and more
- Office and Institutional furniture: lecture hall and auditorium seating for colleges and universities, and various components for office furniture
- Construction: components for various aerial lifts, including aerial work platforms, scissor lifts, and vertical man lifts
- Power generation: Sheet metal housings and enclosures for power equipment such as generators, compressors and pumps.
The 5 Secrets to Our Success
The success of Metal Works of High Point is deeply rooted in a set of core values that guide every aspect of our operation. These principles include:
1. Honesty and Integrity
We believe in doing the right thing and fostering trust as the cornerstone of relationships. Understanding and delivering the needs of our clients reflects our commitment to transparency and ethical conduct.
2. Dependability
Success in metal fabrication demands hard work a commitment embraced at Metal Works of High Point. We acknowledge the direct impact of our actions on your business, and we do not take that responsibility lightly.
3. Respect
Respect at Metal Works of High Point extends to teammates, customers, and the community. This fosters collaboration and inclusivity with all the company’s stakeholders. Our respect for clients is evident in every interaction, building enduring partnerships on mutual understanding and appreciation.
4. Innovation
We thrive on big ideas and embrace new technologies to solve age-old problems. By continually exploring new possibilities, we ensure that our clients benefit from cutting-edge solutions that address their evolving needs.
5. Commitment to Excellence
Every day, we illustrate our will to win, our desire for success, and our commitment to helping you reach your full potential. From laser cutting to forming and welding, we bring our best to every project, setting the standard for quality and precision in metal fabrication.
Metal Works of High Point: Your Trusted Partner in Metal Fabrication
Metal Works of High Point is a leader in contract manufacturing with a proven success record spanning thousands of projects in the last three decades! Our specialized services, years of experience, and commitment to growth and innovation ensure high-quality metal fabrication solutions now and for years to come. We can confidently meet the demand for medium- to high-volume orders with competitive lead times, depending upon the project’s scope.
Contact us today to learn more about our custom manufacturing services or request a quote to start your next project!
Commonly Used Materials in Metal Fabrication
Leave a CommentMetal fabrication is the process of shaping, cutting, and assembling metal materials to create various structures and products. It involves welding, machining, bending, and forming techniques to transform raw metal into finished components or structures. This industrial process is widely used in manufacturing, construction, and engineering.
Choosing the right material for metal fabrication is critical since it directly impacts the finished products performance and longevity. It also ensures that the fabricated part or component can handle its intended application. Here are some of the most commonly used materials in this technique:
1. Carbon Steel
Carbon steel is an alloy primarily composed of iron and carbon. It is known for its strength and durability, making it a popular choice in various industrial applications. Moreover, its carbon content typically ranges from 0.05% to 2%, which significantly influences its hardness and strength. It can be further modified through heat treatment to achieve specific properties.
2. Stainless Steel
Stainless steel consists primarily of iron, chromium, and sometimes nickel. Its defining feature is its resistance to corrosion and staining, mostly due to its chromium content. It is used extensively in kitchen appliances and cutlery due to its hygiene and aesthetic appeal. It is also prevalent in construction for its strength and durability and the medical and pharmaceutical fields for its biocompatibility.
3. Galvanized Steel
Galvanized steel has been coated with a layer of zinc to protect it from corrosion. This coating forms a barrier between the steel and the environment, making it highly rust-resistant. It is commonly used in construction for structural components and outdoor applications such as fencing and roofing. In addition, this type is often employed in manufacturing automotive parts and electrical conduits.
4. Aluminum
Aluminum’s exceptional strength-to-weight ratio makes it a lightweight yet sturdy choice, ideal for applications where limiting mass is crucial. Its innate corrosion resistance is also advantageous for outdoor or corrosive environments. Additionally, aluminum’s thermal and electrical conductivity are critical in the aerospace, automotive, electronics, and construction industries.
5. Brass
Adding zinc to copper in brass enhances its strength, malleability, and corrosion resistance. It also has an appealing golden hue, which makes it a preferred choice for decorative elements and architectural features.
Furthermore, brass is commonly employed in fabricating musical instruments due to its acoustic qualities and resonating ability. Examples of musical instruments include trumpets, trombones, and saxophones.
6. Copper
Copper is known for its excellent electrical and thermal conductivity, making it the go-to material in electrical wiring, plumbing systems, and heat exchangers. Its malleability allows for intricate designs and precise shaping, often seen in decorative artwork and roofing applications. While copper does tend to oxidize over time, this characteristic can also provide a unique patina to artistic pieces.
Metal Works of High Point for Your Metal Fabrication Needs
At Metal Works of High Point, we offer high-quality fabrication services for diverse sectors and applications.From intricate designs to complex geometries, our state-of-the-art technology ensures that each process is executed flawlessly, delivering results that exceed expectations. Whether you need high-volume production custom parts or precise pieces, our team can bring your ideas to life!
Contact us today to learn more about our services.
Sheet Metal Fabrication Finishing With Powder Coating
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Sheet metal fabrication transforms raw materials into functional and aesthetic components. This complex technique unfolds through various stages, each contributing to the emergence of the final product. Among these steps, one pivotal stage stands out finishing. The process enhances the appearance and longevity of the fabricated part and patterns it to fit the projects requirements.
One finishing method that has been gaining recognition for its unique properties and superior results is powder coating. This technique has revolutionized the industry, providing an unparalleled blend of durability, aesthetics, and environmental benefits.
This blog will delve deeper into powder coating, exploring its process and advantages in sheet metal fabrication.
What Is Powder Coating?
Powder coating is a metal finishing process that involves the application of dry, free-flowing, colored powder to a fabricated part or product. The application is done through electrostatic means, where the powder particles are charged and sprayed onto the product’s surface. The coated metal then undergoes heat curing to harden it, forming a solid “skin” coating.
The process begins with preparing the surface of the metal product. This often involves cleaning and sanding the surface to ensure the powder adheres properly. Then, the coating is applied using an electrostatic spray gun. After the application, the product is placed in an oven undergoing heat curing. This process hardens the powder, forming a solid, durable, and visually appealing skin coating.
Powder Coating vs. Conventional Liquid Paint
While both conventional liquid paint and powder coating are used for metal finishing, there are notable differences between them. Primarily, powder coating does not require a solvent. This is because the coating is applied via electrostatic means, which allows the powder to adhere to the surface of the product without the need for a liquid medium.
Once sprayed, the product is cured under heat to form the solid skin coating. This process eliminates waiting for the product to dry, as would be the case with liquid paint.
Powder Coating in Sheet Metal Fabrication
Powder coating offers several advantages in sheet metal fabrication. Among them are the following:
- Durability: Powder coating provides components with a durable finish that can withstand harsh conditions better than others.
- Aesthetic: It also offers greater visual appeal, with a wide range of colors and finishes that can be leveraged to customize a part or product.
- Sustainability: This finishing process is environmentally friendly, producing fewer volatile organic compounds (VOCs) than liquid paint.
Experience the Power of Powder Coating With Metal Works of High Point
At Metal Works of High Point, we provide reliable, visually appealing, and environmentally friendly solutions for your sheet metal fabrication projects. Our team of experts understands the unique benefits that powder coating brings to the table. Hence, you can depend on us to provide you with a finish that meets and exceeds your expectations.
We also offer various other services, including laser cutting, CNC forming and machining, welding, and other finishing techniques. We’re committed to guiding you through every step of your sheet metal fabrication journey, ensuring you receive an outstanding final product.
Contact us today to learn more about how we can bring your vision to life!
MIG vs. TIG Welding in Sheet Metal Fabrication
Leave a CommentElectric arc welding is crucial in sheet metal fabrication because it creates strong, durable bonds between metal pieces. Among the numerous electric arc welding methods, Metal Inert Gas (MIG) and Tungsten Inert Gas (TIG) welding stand out for their quality, efficiency, and versatility.
This blog will compare MIG vs. TIG welding and help you determine which method is best suited for your specific projects.
Comparing MIG vs. TIG Welding
Choosing between MIG and TIG welding involves a thorough assessment of multiple factors. These include material type and thickness, required production speed, weld appearance, quality expectations, the welder’s skill level, and budget constraints.
MIG welding is often preferred for projects that need high production rates and user-friendly operation, making it suitable for various applications. Conversely, TIG welding offers precision and clean, aesthetic welds that are ideal for intricate or specialized tasks.
MIG Welding
Also called Gas Metal Arc Welding (GMAW), MIG welding uses a continuous solid wire electrode fed through a welding gun to fuse base materials. A shielding gas is channeled through the welding gun to protect the weld pool from contamination by the ambient air.
Pros
MIG welding has a high production rate and user-friendly nature, making it suitable for various applications. Some of its other key advantages include:
- High production rate: This welding type significantly increases overall productivity, as its faster than other methods.
- Ease of use: MIG welding is suitable for both novice and seasoned welders.
- Versatility in materials:A range of metals including mild steel, stainless steel, and aluminum can be welded using this technique.
Cons
However, MIG welding also has some disadvantages:
- Limited outdoor use: The shielding gas can be easily blown away in windy conditions, making it less suitable for outdoor applications.
- Less precise than TIG welding: This technique offers good control but is generally less precise than TIG welding.
- Higher equipment cost: Required equipment can be more expensive than other welding methods, particularly considering the cost of consumables such as shielding gas and wire electrodes.
TIG Welding
TIG welding, or Gas Tungsten Arc Welding (GTAW), employs a non-consumable tungsten electrode to form an arc between the electrode and base material. A separate filler rod adds material to the weld pool, while a shielding gas protects the weld from contamination.
Pros
TIG welding is renowned for its high precision and control, making it ideal for applications requiring clean and aesthetically pleasing welds. Other advantages of TIG welding include:
- High precision and control: TIG welding offers greater control over the welding process, allowing for precise, high-quality welds.
- Clean and aesthetic welds:Due to their precision, this method produces clean, visually appealing welds with minimal spatter and post-weld cleanup.
- Versatility in material thickness: TIG welding can accommodate a broad spectrum of material thicknesses, from thin sheets to thick plates.
Cons
TIG welding also presents certain drawbacks:
- Slower production rate:Compared to MIG welding, this technique usually has slower speeds.
- Requires more skill and experience:TIG welding is considered to be more difficult to grasp for inexperienced or new welders.
- Limited material compatibility: This method is less compatible with certain materials, such as cast iron and some alloys.
Discover the Perfect Welding Solution With Metal Works of High Point
At Metal Works of High Point, we understand the importance of selecting the right welding technique for your sheet metal fabrication projects. Our skilled team will guide you and help you decide if MIG or TIG welding suits your needs best.
Our other services include laser cutting, CNC forming and machining, finishing services, and more. Contact us today to learn more!
CNC Machining Sheet Metal Fabrication Techniques
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Computer numerical control (CNC) machining sheet metal fabrication is a sophisticated manufacturing technique employing machines to precisely shape and cut sheet metals. It combines the precision and automation capabilities of CNC technology with the versatility and malleability of sheet metal. This creates customized forms, intricate structures, and meticulously crafted components.
The method employs various tools such as lasers, routers, or milling cutters to process the sheet metal according to the specified design. The software controls the machines movement and operation, ensuring consistent and uniform execution throughout fabrication.
The following techniques demonstrate the adaptability and accuracy of CNC sheet metal fabrication:
1. Laser Cutting
Laser cutting is a highly efficient process utilizing a high-powered laser beam to cut through the sheet metal. First, the design of the desired shape or pattern is created using computer-aided design (CAD) software. Next, the digital design is transferred to the laser cutting machine with a laser source and a focused lens.
The laser cutter generates a concentrated laser beam, typically using a medium like carbon dioxide (CO2) or fiber. The beam is directed toward the sheet metals surface and rapidly heats and melts the material along the predetermined cutting path. Moreover, laser cutting is widely used in the automotive, aerospace, electronics, and architecture industries.
2. Plasma Cutting
Plasma cutting uses a high-velocity jet of ionized gas, known as plasma, to melt and remove the material. The cutting machine has a plasma torch containing a small nozzle and an electrode. When the torch is activated, an electric arc is formed between the electrode and the workpiece, ionizing the gas and creating plasma.
The plasma is directed towards the surface, rapidly heating and melting the material. This intense heat, coupled with the high-velocity plasma jet, effectively blows away the molten metal, resulting in a clean and precise cut. The cutting depth and quality can also be finely tuned by adjusting the speed, gas flow rate, and power level.
3. Bending
Bending is a metal forming technique where force is employed to alter the shape or angle of a flat sheet of material. This process utilizes specific tools or machinery to apply bending forces exceeding the elastic limit, resulting in lasting deformation. It also facilitates the creation of complex geometries, including bends, curves, or folds, enabling the production of intricate components.
4. Shearing
Shearing removes material by a perpendicular force to the sheet metal, resulting in a straight-line cut. In this process, two sharp blades are used one positioned above the material and the other below. The blades are then brought together with high force, causing the material to separate along the desired cutting line. It is commonly used for cutting sheet metal into straight and accurate pieces, such as strips or plates.
5. Embossing/Engraving
Embossing or engraving creates raised or recessed designs, patterns, or text on the material’s surface. Embossing involves imparting a three-dimensional raised structure onto the metal, while engraving creates a sunken or recessed design. These techniques are typically achieved using specialized tools or dies that apply pressure or remove material from the surface.
Both techniques can serve functional and decorative purposes, adding visual appeal, branding, or labeling to sheet metal components. As a result, they are commonly used in industries like automotive, signage, electronics, and packaging, where customization and aesthetics are paramount.
Other CNC machining techniques include the following:
- Notching:This process removes a portion of the sheet metal by cutting or punching to create interlocking or mating features.
- Lancing:This involves cutting or slitting the sheet metal to create tabs or flaps. The tabs can be folded to provide additional structural support or to make connections between different parts.
- Swaging: This is the reduction or expansion of the diameter of a cylindrical or tubular section of sheet metal.
- Spinning: This forming technique creates symmetrical and hollow shapes in sheet metal using lathes, rollers, or tool presses.
Choose Metal Works of High Point for Premium CNC Machining Services
At Metal Works of High Point, we specialize in sheet metal fabrication services that go beyond traditional manufacturing. We aim to optimize your processes and reduce production expenses while delivering high-quality results. Our expertise and state-of-the-art 3-axis cutting systems also enable us to handle all your custom needs efficiently and precisely.
Contact us today to learn more about our services!
Laser Cutting Sheet Metal Fabrication Techniques
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The sheet metal fabrication industry has significantly transformed with the advent of laser technology. This innovation enables the creation of intricate designs and shapes that were previously unattainable through traditional methods. Additionally, laser cutting achieves precise cuts by using highly focused beams of light, resulting in faster production times, minimal waste, and maximum precision.
This article will explore the various techniques involved in laser cutting sheet metal. We will also cover the types of lasers used in modern metal fabrication.
Advanced Laser Cutting Methods
The use of lasers has increased the flexibility and customization of sheet metal fabrication. Here are some of the most cutting-edge procedures used by manufacturers today:
Multi-Axis Cutting
The multi-axis cutting technique involves using a machine that can cut along multiple axes. This means the laser can move in various directions, allowing greater flexibility in cutting complex shapes and designs. Multi-axis cutting also enables the production of more intricate parts, reducing the need for post-processing and improving the quality of the final product.
High-Power Cutting
High-power cutting uses lasers with greater wattage to cut through thick metal sheets. This technique particularly benefits heavy-duty applications, such as the aerospace and automotive industries. Furthermore, it can cut through metals up to 25 mm thick, resulting in a faster production process and reduced need for manual finishing.
Pulsed Cutting
Pulsed cutting involves applying brief pulses of laser light to slice through sheet metal. This technique is especially useful for cutting thin materials like aluminum and stainless steel. This method reduces the amount of heat generated during the cutting process. This minimizes the risk of warping or damaging the material.
Fusion Cutting
Fusion cutting melts and fuses the material to achieve a precise cut. This technique is best suited for cutting thick materials and precision cutting complex shapes. The laser beam is directed onto the metal surface, melting and vaporizing to make a narrow cut. Finally, the final cut is extremely exact and clean, eliminating the need for additional finishing processes.
Flame Cutting
Flame cutting is a process that combines a laser with a high-temperature flame. Initially, the laser is used to heat the material, and then the flame is used to melt and cut through the metal. This technique is a cost-effective substitute for plasma cutting and is often used in construction and manufacturing industries.
Types of Lasers for Sheet Metal Cutting
Different lasers are used for various sheet metal cutting applications, each with unique features and benefits. Discussed below are three of the most popular laser types:
CO2 Lasers
CO2 lasers are among the most commonly used lasers for sheet metal cutting. They use a gas mixture of carbon dioxide, nitrogen, and helium to generate the laser beam. They also have a wavelength of 10.6 microns, making them suitable for cutting metallic and non-metallic materials. Lastly, they offer high precision and can cut through a wide range of thicknesses.
Fiber Lasers
Fiber lasers use a doped fiber as the lasing medium to produce a beam. As a result, they are highly efficient, require less maintenance, and have a higher power output than CO2 lasers. Moreover, they have a wavelength of 1.06 microns, ideal for cutting metals like stainless steel, aluminum, and copper. Fiber lasers can also produce high-quality cuts at high speeds.
Crystal Lasers
Crystal lasers are solid-state lasers that use a crystal as the lasing medium. The most common types of crystals used are neodymium-doped yttrium aluminum garnet (Nd:YAG) and neodymium-doped yttrium orthovanadate (Nd:YVO4). They are highly efficient and offer high beam quality and stability, making them popular for various applications.
Metal Works of High Point: Your Partner for High-Quality Laser Cutting Solutions
At Metal Works of High Point, our metal laser services can help streamline your fabrication process and lower production expenses! We prioritize providing our customers with high-quality manufacturing services at a reduced cost. We can also handle all your custom cutting needs with our team of skilled professionals and cutting-edge 3-axis cutting systems.
Contact us today to learn more about our services and capabilities!