One word can sum up what the difference is between standard metal fabrication and custom fabrication, and that word is value. While you may associate “costly” with “custom,” that isn’t necessarily always the case when you are looking at the future value of a project.
Custom fabrication starts with an inspection of the project to determine the correct materials and the method that should be used to manufacture the custom design at the lowest possible cost. The expectation is to produce more high-quality and reliable results that will provide value in the long run.
Establishing Design Intent
Having a solid, thorough plan is necessary to reaching the desired result of adding value to your project. A full-service fabricator will be able to take an engineering drawing or a standard industrial plan and create a design detailed enough to achieve your desired result, no matter the complexity.
During this part of the process, the fabricator may find it necessary to test and refine plans to ensure the project design meets all necessary industry regulations and requirements, and identify the materials that will be required.
Every custom fabrication could begin with Pro Nest, MTC Shape Cutting, or AutoCAD files — it could even start with a basic hand-drawn plan. Having the right engineering expertise ensures your project has met every possible specification that can add value before actual fabrication begins.
Some ideal projects for this process include feed tanks, grain tanks, hoppers, and silos with metering of dry solids; liquid food storage with quality control capability; and custom wrap-around spiral staircases with crossover platforms.
Metal Cutting & Forming
Before metal cutting begins, the fabricator has to decide which method should be used based on the type of metal and its thickness. Laser cutting is highly effective for light metal or heavy steel plates demanding precise tolerances. CNC machines may be used for intricate steel metal shapes requiring remarkable precision. Plasma tables may be used on thick metal plates when carving circular holes or elaborate shapes. Sawing may be appropriate for large beams serving as structural steel backbones, and plate shears are the most cost-effective way to cut simple shapes.
Equipment used to form metal may include mechanical and CNC hydraulic press brakes, plate and rolling machines, CNC punching or beam punches, and multi-function ironworkers used to bend, punch, and shear the metal. The success of metal forming depends on selecting the correct machines — hiring a full-service metal fabricator with the necessary equipment in-house saves time and money.
Custom Welding and Assembling Techniques
Custom welding and assembly techniques can guarantee that metal fabrications meet industry-specific standards. A custom fabricator that works with a quality control (QC) program is more likely to meet industry requirements, which adds value to your project.
Your metal fabricator should test all assemblies and subassemblies together to ensure the final project functions as expected. Before partnering with a metal fabricator, request documentation showing welder certifications, including compliance with Canadian Welding Bureau (CWB) standards, Welding Procedure Specifications (WPS) conforming to ASME Section 9 practices, and qualifications to weld structural steel based on AWS D1.1.
When shipping fabricated components, they should ship in the most complete form possible — large assemblies should ship together so workers can complete assemblies quickly on-site, drastically reducing labor expenses and project timelines.
Finishing
Finishing is the final stage in the process and extends the life of custom metal fabrication pieces, ensuring resistance to chemicals, tarnishing, and corrosion.
Finishing techniques that may be used include metal bead blasting or other surface prep that allows paint or coating to adhere; custom painting and drying in controlled paint booths, which expedites drying time and ensures proper hardening; hot-dip galvanizing to coat every inch of the piece to prevent moisture damage; and metal powder coating for decorative finishing.
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Jim Anderson
Engineered Mechanical Systems
Dedicated to precision, quality, and building lasting relationships through expert fabrication and machining since 1990.