Metal Fabrication

Metal fabrication encompasses multiple process categories:

Cutting:
Separating material to size and shape:
- Shearing: Straight cuts on sheet, powered guillotine blade
- Sawing: Band saw or cold saw for bar/structural
- Plasma Cutting: High-temperature ionized gas, versatile
- Laser Cutting: Precise, clean edges, CNC controlled
- Waterjet: No heat-affected zone, any material
- Oxy-Fuel: Thick steel, low cost, portable

Forming:
Shaping without removing material:
- Bending/Press Brake: Create angles and flanges
- Rolling: Curves in plate and shapes
- Stamping/Punching: High-volume forming
- Deep Drawing: Complex 3D shapes from sheet
- Spinning: Symmetrical parts on lathe-like equipment

Machining:
Material removal for precision features:
- Drilling: Holes of various sizes
- Milling: Surfaces, pockets, profiles
- Turning: Round features on lathe
- Grinding: Precision finishing
- Threading: Tapped holes, threaded studs

Joining:
Assembling components:
- Welding: Fusion of materials (MIG, TIG, stick)
- Mechanical Fastening: Bolts, screws, rivets
- Adhesive Bonding: Specialized applications
- Brazing/Soldering: Lower temperature joining

Finishing:
Surface treatment:
- Grinding/Deburring: Remove sharp edges
- Painting/Powder Coating: Corrosion protection, appearance
- Plating: Zinc, chrome, nickel for protection
- Passivation: Stainless steel treatment

Effective fabrication requires understanding engineering drawings:

Drawing Types:
- Detail Drawings: Individual part specifications
- Assembly Drawings: How parts fit together
- Weldment Drawings: Welded assemblies
- Erection Drawings: Installation at site

Drawing Elements:
- Title Block: Part number, material, revision
- Views: Orthographic projections showing all features
- Sections: Cut-away views revealing internal features
- Details: Enlarged views of complex areas
- Dimensions: Sizes and locations
- Notes: Special requirements, processes

Geometric Dimensioning and Tolerancing (GD&T):
- Form: Flatness, straightness, circularity
- Orientation: Perpendicularity, parallelism, angularity
- Location: Position, concentricity, symmetry
- Runout: Surface variation during rotation
- Profile: Complex surface requirements

Material Specifications:
- Steel: ASTM A36, A572, A500, etc.
- Stainless: 304, 316, 17-4 PH
- Aluminum: 6061-T6, 5052, 3003
- Size/Form: Sheet, plate, bar, tube, structural shapes

Process Planning:
1. Review all drawings and specifications
2. Identify material and quantity requirements
3. Determine operation sequence
4. Select equipment and tooling
5. Estimate time and cost
6. Plan quality checkpoints

Bill of Materials (BOM):
List of all components:
- Part numbers
- Quantities
- Materials
- Sizes
- Purchasing information

Fabrication shops utilize diverse equipment:

Cutting Equipment:

Shears:
- Capacity: thickness and width
- Blade angle affects cut quality
- Back gauge for accurate positioning
- Hydraulic power for thicker material

Plasma Tables:
- CNC controlled cutting paths
- Handle various thicknesses
- Moderate precision (±1/32")
- Lower cost than laser

Laser Cutters:
- High precision (±0.005")
- Clean edges, minimal heat effect
- Fast for thin materials
- Higher operating cost

Forming Equipment:

Press Brakes:
- Tonnage determines capacity
- CNC back gauge for accuracy
- Various die profiles available
- Critical for precision bending

Rolls:
- Plate rolls for cylinders
- Section rolls for structural shapes
- Capacity by thickness and diameter

Ironworkers:
- Multi-function: punch, shear, notch
- Handle structural shapes
- Efficient for varied work

Hand Tools:
- Grinders (angle, die, straight)
- Drills (magnetic, hand-held)
- Files, deburring tools
- Measuring instruments
- Layout tools (squares, scribes)

Fixturing:
- Welding tables with slots
- Positioning clamps
- Custom fixtures for production
- Modular fixturing systems

Material Handling:
- Overhead cranes
- Forklifts
- Roller conveyors
- Pallet jacks

Metal fabrication offers progressive career opportunities:

Entry Positions:

Helper/Laborer:
- Material handling
- Shop cleanup
- Basic operations assistance
- Learn shop operations
- $30,000-$40,000

Machine Operator:
- Run specific equipment
- Follow work orders
- Basic quality checks
- $35,000-$50,000

Skilled Positions:

Fabricator:
- Multiple operations capability
- Blueprint reading
- Layout and setup
- Quality responsibility
- $45,000-$65,000

Welder/Fabricator:
- Combined skills
- Broad capability
- Higher value work
- $50,000-$75,000

CNC Operator/Programmer:
- Operate CNC equipment
- Program from drawings
- Optimize processes
- $50,000-$75,000

Leadership:

Lead Person:
- Supervise small team
- Coordinate work flow
- Problem solving
- $55,000-$75,000

Shop Foreman:
- Manage department
- Schedule work
- Quality responsibility
- $65,000-$90,000

Estimator/Project Manager:
- Quote jobs
- Manage customer projects
- Technical sales
- $60,000-$100,000

Industries:
- Structural steel
- Industrial equipment
- HVAC/ductwork
- Architectural metal
- Machine shops
- Job shops

Skills for Advancement:
- Welding certifications
- CNC programming
- Blueprint reading proficiency
- Leadership development
- Estimating capability

Education Options:
- Trade school programs
- Apprenticeships
- Community college
- On-the-job training