Laser cutting is exciting and dramatic, so it’s not surprising that it gets most of the attention in modern metal fabrication. However, there is so much more involved in the full fabrication process. It’s the less dramatic steps such as forming and powder coating that give full shape to the final product. 

If you’ve ever wondered what happens after the initial cut, this piece gives a fascinating peek into the world of modern metal fabrication. Discover the full fabrication lifecycle and learn why in-house finishing improves turnaround times and product durability. 

What Happens After the Cut

Laser metal cutting is a high-precision process that burns or melts through metals to cut them into the desired pieces. It offers a clean edge and superior accuracy for complex projects with tight tolerances. But it’s only just the beginning of the metal fabrication process. Here are the steps that occur after the initial cut and help transform the metal sheet into a finished product using the right tools. 

Cleaning

After laser cutting, the metal is typically cleaned with deburring tools or with methods such as sanding or wire brushing. Chemical agents like mineral spirits, acetone, or alcohol may be used to remove residues from the metal’s surface. For more precision cleaning, manufacturers may use ultrasonics, nitric or citric acid passivation, or fiber laser cleaners. 

Deburring

To achieve a smooth finish after laser cutting, metal parts may be sent through a deburring and edge-cleaning process. This helps remove any sharp edges or dross that might remain after laser cutting. Even though laser cutting is valued for its ability to create precise, smooth finishes, deburring can make metal edges even smoother. Deburring is achieved using processes such as sanding, grinding, or filing to smooth metal surfaces after they’ve been cut.  

Forming

After cleaning and deburring, sheet metal goes through a forming process. This typically involves the use of specialized dies, presses, and rollers to shape the cut metal into the desired form. Forming may be achieved through the use of mechanical forces like compression, bending, or stretching. Metal is more pliable when it’s formed at high temperatures (a process called hot working). However, it can also be formed at room temperature (referred to as cold working). 

Bending

Metal bending is a specific type of metal forming. While all metal bending falls under the umbrella term of “forming,” not all metal forming is considered bending. Bending involves using carefully applied force to create angled bends. This is typically done with a press brake. Forming, on the other hand, reshapes metals into various forms using methods like stretching, stamping, forging, and rolling. 

Precision Machining

The machining portion of the metal fabrication typically occurs after forming and bending the metal into the generally desired shape. The primary purpose of machining is to remove excess material and refine features using powered tools such as lathes, drills, and CNC mills. Machining fine-tunes raw stock into functional, finished components with a high degree of accuracy. 

Welding

Welding involves joining two different metal components together to form the final structure. Welding sometimes occurs before the precision machining step. However, it more frequently comes afterward. Common welding methods include:

• Tungsten Inert Gas (TIG) Welding: This refers to the process of using a non-consumable tungsten electrode to create heat. This arc welding process is precise and ideal for non-ferrous, thin metals such as titanium, aluminum, and stainless steel. 
• Metal Inert Gas (MIG) Welding: This versatile welding method uses a consumable, continuously fed wire electrode to join separate metal pieces. It’s a beginner-friendly type of arc welding that works well for stainless steel, steel, and aluminum.
• Laser welding: This high-precision welding method creates clean, strong, and deep welds with minimal distortion. While TIG and MIG welding often uses filler metal, laser welding doesn’t require filler metal. It works well on metals that are thin to medium-thick. 

Blasting

Blasting (also known as sandblasting or abrasive blasting) is an important part of the metal fabrication process. It uses a stream of forcibly-applied abrasive materials to smooth, clean, or roughen metal surfaces. Manufacturers may use glass beads, sand, or steel grit to blast metal surfaces under high pressure. This process prepares the metal surfaces for the final part of the fabrication process: powder coating. 

Powder Coating

Powder coating is a dry finishing process used in metal fabrication. It involves spraying finely ground particles that are electrostatically charged onto grounded metal parts. Once sprayed with the powder coating, the metal parts are cured at high temperatures in a specialized oven. This high-heat process melts the powder into a scratch- and corrosion-resistant protective finish. Powder coating offers a wide range of textures and colors to suit each project’s particular needs. 

Get the Turn-Key Crafted Metal Parts You Need

The metal fabrication process is complex and involves many important steps beyond the initial laser cut. If any of these steps aren’t completed with care and precision, it could negatively impact the quality and reliability of the final piece. If you work in an industry that requires precision-fabricated metal parts, it’s wise to partner with a turn-key manufacturer that adheres to the highest quality standards. For the best results, look for a supplier that uses high-tech software and machinery to provide reliable and accurate fabricated metal parts.