5 Common Problems in Custom Sheet Metal Fabrication

Custom sheet metal fabrication can look straightforward on a drawing.

But problems often appear when the design moves from engineering to production.

After working with custom metal components, we have found that many manufacturing issues are not caused by the equipment itself. They start with the design, material selection, or unclear requirements.

Here are five common problems to consider before production.

1. Cracking During Bending or Forming

Cracking can occur when the material, thickness, bend radius, and forming direction are not properly considered.

Different materials behave differently during forming.

A design that works well with one material may require adjustment when the material changes.

2. Deformation Around Holes

Holes located too close to bends or forming areas can deform during production.

This can affect assembly, fastener alignment, or dimensional accuracy.

Hole locations should therefore be reviewed together with the surrounding bends and forming features.

3. Excessive Burrs

Cutting operations can leave burrs on sheet metal parts.

The acceptable level depends on the application.

Parts used in assemblies or handled by operators may require additional deburring, while other applications may have different requirements.

The important point is to define the requirement clearly before production.

4. Dimensional Variation

Formed sheet metal parts may experience dimensional variation due to material properties, tooling, springback, and production conditions.

Critical dimensions should therefore be identified rather than applying extremely tight tolerances to every feature.

5. Surface Finish Problems

A surface finish requirement should match the actual application.

Brushing, polishing, plating, powder coating, painting, and other treatments can affect both appearance and cost.

If the surface is visible or needs to meet a specific functional requirement, the drawing should clearly define it.

Preventing Problems Before Production

Many sheet metal fabrication problems can be reduced through an engineering review before production.

A useful review should consider:

• Material specification

• Sheet thickness

• Critical dimensions

• Tolerances

• Bend radius

• Hole locations

• Forming direction

• Burr requirements

• Surface finish

• Assembly requirements

The earlier these factors are reviewed, the easier it is to avoid expensive changes later.

For custom OEM components, manufacturing should not begin with the question, "Can we make this?"

A better question is:

"Can we make this consistently, economically, and according to the required function?"

That is where practical sheet metal fabrication experience makes a difference.

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