Sheet Metal Fabrication Process Guide | Ahner Industrial

Jun 20, 2025

Updated: 3 days ago

Sheet metal fabrication turns flat steel, stainless steel, or aluminum into production-ready parts through cutting, forming, joining, and finishing. For engineers, buyers, and plant managers, understanding those steps makes CAD reviews and quote comparisons more useful. This guide explains the common process flow and shows where Ahner Industrial’s Sandusky, Ohio shop fits.

What Is Sheet Metal?

Sheet metal is flat stock produced in a range of gauges and thicknesses. Carbon steel is strong and economical, stainless steel adds corrosion resistance, and aluminum reduces weight. Ahner’s online quote workflow currently standardizes A1011 carbon steel, 304 2B stainless steel, and 3003 aluminum. Other materials and requirements can be reviewed through a custom quote.

From Sheet to Finished Part: Four Common Steps

The sheet metal fabrication process typically involves several key steps. Let’s walk through them.

1. Cutting: Laser and Plasma

Cutting creates the flat profile before forming or assembly. Ahner uses fiber laser cutting for clean, repeatable sheet-metal geometry and plasma cutting for appropriate heavier material. Buyers with finalized CAD can also review the online laser-cutting workflow.

Laser cutting: A focused laser produces detailed profiles and clean, repeatable edges. Ahner’s online workflow accepts DXF for finalized flat geometry and STEP or STP for flat or supported formed parts.

* Plasma Cutting: This uses a focused beam of hot plasma to cut through thicker materials. It's often a more economical choice for heavier-gauge steel and simpler shapes.

2. Forming: Press Brake Bending

Press brakes use a punch and die to create controlled bends. Ahner operates five press brakes for prototype and production work. The online sheet-metal bending workflow supports parts within its published 120-inch bend-length and 170-ton limits; larger or more specialized parts can be reviewed against the shop’s broader custom-forming capacity.

3. Joining: MIG, TIG, Robotic and Laser Welding

Cut and formed parts may be joined into weldments or assemblies. Ahner selects the process from the material, joint geometry, quantity, appearance, and strength requirements rather than treating every weld the same.

* MIG Welding: (Metal Inert Gas) This is a versatile and common welding process used for joining carbon steel and aluminum. It uses a shielding gas to protect the weld from atmospheric contamination.

* TIG Welding: (Tungsten Inert Gas) Also known as GTAW (Gas Tungsten Arc Welding), TIG offers exceptionally clean and precise welds. It’s frequently used for stainless steel, aluminum, and other critical applications where weld quality is paramount.

* Robotic Welding: We have a robotic MIG cell, which allows for high-volume, consistent welding with increased precision and efficiency. This is especially valuable for repetitive weld patterns.

* Laser Welding: A focused laser beam is used to melt and join the metal parts. It’s suitable for a range of materials and provides a narrow, deep weld.

4. Finishing: Deburring, Grinding and Coating

Finishing can include deburring, grinding, polishing, painting, or powder coating. The required edge condition, coating specification, color, masking, and cosmetic expectations should be stated on the print or purchase requirements before production.

What to Include in a Sheet Metal Quote

Provide the CAD file and revision, material and thickness, quantity, tolerances, bend information, hardware, weld symbols, finish requirements, inspection needs, and delivery location. Use DXF for finalized flat cut geometry or STEP/STP when the 3D or formed model carries important manufacturing intent.

Ahner Industrial combines two lasers, five press brakes, welding processes, experienced review, and a 45,000-square-foot Sandusky facility. Cutting, forming, review, and fulfillment stay with the same manufacturing team instead of being passed through an anonymous marketplace.

Start an online sheet metal quote for supported DXF, STEP, or STP parts, or use Ahner’s custom quote form for larger parts, special materials, welding, finishing, assemblies, or requirements outside the automated rules.

Questions before quoting? Call 419-626-6641 or email sales@ahner-industrial.com.