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Deciding Between Sheet Metal and Machining Components

Tag Archive: Prototyping

  1. Deciding Between Sheet Metal and Machining Components

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    Deciding between Sheet metal and machining components is one of the first decisions engineers make during the design process. This decision impacts cost, lead time, whether there are additional steps in the fabrication assembly line, and overall performance of components. Both options have their advantages and deliver high-quality projects. Here is a guide to help determine which manufacturing process best fits your sheet metal needs. 

     

    How Complex Is It?

    Choose sheet metal fabrication when your products are lightweight brackets, chassis, or enclosures, and the design is made from a flat pattern, has flanges, or requires straightforward forming. 

    Choose machining if the part requires tight contours, deep cavities, and pockets. Machining is best for components with internal features or multi-plane designs. If the geometry can be created from a flat pattern, metal fabrication is the right option; if not, machining is the way to go. 

     

    How is the Pricing Different?

    With sheet metal fabrication, there is less material waste, production is typically faster (especially with TEDCO’s Amada ENSIS 3015AJ Laser), and costs are adjusted for bulk quantity projects. 

    You can see higher machining costs due to material removal and cycle times. Components that have more complexities add to labor costs and longer lead times. For many designs, the cost difference between sheet metal vs machined components becomes clear once strength, geometry, and tolerances are considered.

     

    Tight Tolerances 

    Sheet metal is best for standard commercial tolerances and bend variability. Machining is best for tight tolerances, mating surfaces, and critical fits. When precision drives product performance, a machined component typically offers the accuracy required.

     

    Material Requirements 

    Sheet metal works well with aluminum, stainless, and cold-rolled steel. It is ideal for thinner materials and lightweight components.  Sheet metal relies on bends and formed features for rigidity. 

    Machining supports thicker, high-strength components, handling a wide range of materials, and tough alloys. If the parts must withstand significant loads or require tight tolerances, machining may be the better choice. 

    Scalability 

    Scalability refers to whether there are plans for bulk production. Sheet metal is excellent for prototypes and large-volume projects. It works best for projects with minimal tooling and fast iterations. 

    Machining is best for low-to-medium volume jobs, as it is costly at large quantities because there is less automation in machining. Prototyping needs, production goals, and cost target all influence the decision process, so discuss in advance with your fabricators. 

     

    When a Hybrid of the Two Makes Sense

    Tedco has learned over the years that many project assemblies work best when sheet metal and machined components are combined. Tedco has built a close network of machinists who work directly with us for hybrid jobs. Combinations likely include enclosures with machined internal parts, Sheet metal housing with machined interfaces, or lightweight designs that require both rigidity and accuracy. 

     

    Choosing between machining and sheet metal components depends on the requirements of the project. Be sure to take a look at the necessary tolerances, strength, geometry, and the volume and scale of the project. Most importantly, share the budget with your engineering team to make adjustments when necessary. Both processes bring unique advantages, and many projects benefit from a hybrid approach. At TEDCO, we help clients decide the best manufacturing method for early prototypes through full-scale production.

  2. Back to Basics: How to Get a Prototype Manufactured

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    There are recurring customers who have been with us for decades and order bulk-quantity productions. There are also people brand new to the world of sheet metal fabrication who walk through TEDCO’s doors all the time.

    Back to Basics: How to Get a Prototype Manufactured Once in a while, it is best to go back to basics and explain processes that are at the very foundation of what we do, such as how to get a prototype manufactured. 

    Precision sheet metal prototyping gave TEDCO the foundation to execute the larger projects we do today. When our company was just a father, son, and a small metal shop, prototyping was all we did. 

    Prototyping is the process of quickly building a simplified version of a product to test ideas, gather feedback, and, in some cases, go back to the drawing board for revisions.

    Let’s Talk Steps 

    Preparing Your Digital Model 

    Before requesting an estimate from TEDCO, you have to create a DFM, or Design for Manufacturability. You have to ensure your design uses standard material thicknesses and consistent bend radii, as well as welding, hardware, or finishing call-outs.  Keep in mind to avoid overly complex tolerances or geometries to keep costs low. 

    Manufacturers require a 3D STEP file, DXFs, and possibly other formats, depending on the software used to read the drawing.

    Choose Your Material

    It is best to stick to standard common metal materials like Aluminum, Stainless Steel or Cold-Rolled Steel for the fastest turnaround and lowest costs. If this prototype will not make it to final production and will need alterations before signing off on larger quantities, it’s best to use thinner, less expensive materials. Also smart to choose an in-stock selection from vendors to reduce lead times. Back to Basics: How to Get a Prototype Manufactured

    Submitting Request for Quote

    Now you can email TEDCO directly, or submit on our request for quote form on the TEDCO website to get pricing and lead time before taking the next steps. If there are any further questions for our executive programmer, you can arrange a meeting to discuss the project at hand. Our experts will help you agree on materials, hardware needed, or how to save costs by eliminating certain aspects of the prototype. Coming in for a meeting also presents the opportunity to tour the shop or talk about machining needs.

    This is also the time to decide on finishing treatments such as powder coating, anodizing, or chem film applied for aesthetics or for corrosion resistance. 

    Fabrication Process 

    Once the quote is approved, the purchase order is submitted, and the due date is settled upon, it is time to get this project into fabrication. In the next few months, we will dive deeper into the fabrication steps and the machines used throughout the process. Once completed, the customer typically takes the prototype back to their team or on-site, to see if the part will work as designed. If there are any further revisions that have to be made before the part goes into production, TEDCO is here for the next round of prototyping.