Custom metal fabrication transforms ordinary metal sheets or bars into finished components that go into products we use every day.
To get to that end result, technicians must bend and fold the raw metal at the necessary angles to achieve the desired shapes.
Metaltech uses state-of-the-art press brakes to form complex parts and heavy components efficiently and safely. Metal forming lets us create high quality parts for industries including agriculture, heavy equipment, construction, manufacturing and more. We fabricate intricate parts based on precise specifications as captured in the design and engineering phase of the process.
Custom metal forming includes a range of techniques for shaping steel, aluminum, copper, specialized alloys and other metals. Common methods include pressing, rolling and drawing. Because most metals are ductile, they will stretch or bend before they break. Once we cut your metal to the right size, our technicians follow a detailed blueprint in order to bend the piece into a recognizable, functional shape.
Metal Forming Basics
The metal forming process uses mechanical force to bend, stretch or compress the metal into a range of custom shapes.
Types of Metal Forming
Bulk forming uses large, thick metal pieces, while sheet forming works with thinner metal sheets. Different metal forming processes may be selected depending upon the project requirements.
- Rolling, also called roll forming, involves passing a metal sheet between two rollers. The process may occur at high temperatures or at room temperature, depending on the desired outcome.
- Drawing is a technique that involves pulling the metal through a die to reduce its diameter or change its shape. The result is an elongated piece that can be used to create wires, tubes and other long, slender components.
- Pressing uses a mechanical or hydraulic press brake to apply pressure that forms the metal into a specific shape.
Uses of Metal Forming
There are many applications for parts created by metal forming, including automotive, machinery, household goods and structural elements for construction. Metal forming is essential for creating parts for the following industries.
- Manufacturing Components: Metal forming is used in manufacturing components for heavy machinery, equipment and tools. It creates parts like structural components, weldments and housings.
- Construction: Building components, such as beams, pipes, cladding materials, and structural components, are fabricated through metal forming processes like rolling, pressing and drawing.
- Consumer Goods: Metal forming is integral for everyday items such as kitchen utensils, appliances, furniture and decorative items.
- Energy: Metal forming is used for power generation equipment, pipelines and renewable energy systems. Examples include wind turbine parts, solar panel frames, energy storage systems and transmission line components.
- Medical Devices: A variety of medical instruments, implants and devices are made through metal forming techniques, with an emphasis on precision, durability and biocompatibility.
- Electronics: Metal forming contributes to the production of electronic components such as connectors and enclosures for electronic devices.
Metals Used in the Forming Process
Many different types of metal can be formed into a wide range of customized shapes to achieve the desired properties.
- Steel: Known for its strength, versatility and affordability, steel is extensively used in various forms across industries like automotive, construction, and manufacturing.
- Aluminum: Strong, lightweight aluminum is used in aerospace, automotive, and construction due to its corrosion resistance and excellent formability.
- Copper: Valued for its electrical conductivity and malleability, copper is used in electrical wiring, plumbing and many industrial applications.
- Brass: A combination of copper and zinc, brass is used for decorative elements, fittings, valves and instruments due to its attractive appearance and corrosion resistance.
- Titanium: Known for exceptional strength-to-weight ratio and corrosion resistance, titanium is found in aerospace, medical implants and high-performance machinery.
- Nickel: Often used in alloys, nickel provides heat resistance and corrosion resistance, making it valuable for industries including aerospace, chemical and electronics.
- Magnesium: Known for its lightweight properties, magnesium is used in aerospace, automotive and electronics industries for reducing the weight of key components.
- Custom Alloys: Alloying metals together, such as brass (copper and zinc), bronze (copper and tin) and various steel alloys (such as stainless steel), enables custom properties like strength, corrosion resistance and conductivity.
How Press Brakes Work
At Metaltech, we use four press brakes manipulate flat blanks and transform them into component parts based on the specified angles. The press brake uses tons of force to bend the sheet metal to shape the end part. Our technicians can bend sheet metal at almost any angle with a variety of die and punches.
- Our high-speed electric press brake works with speed, accuracy and efficiency. It Includes added safety features, making it almost impossible for operators to obtain an injury.
- Our newest and largest press brake includes CNC lifting for heavy materials, which reduces the number of operators required to do the job. It increases productivity and keeps employees safe.
Press Brake Components
A press brake includes the following components:
- The frame offers structural support and stability to withstand the strain produced by the bending process.
- The bed is the base of the press brake. It has a flat surface where the workpiece rests during operation. A V-shaped groove facilitates diverse bending options.
- The ram is a dynamic component that holds a punch, which moves downward during operation and applies force to metal workpiece against a stationary die.
- Mounted on the ram, the punch is the upper tool for shaping metal sheets and comes in different shapes and sizes for customization.
- A die is positioned on bed where it holds a lower tool as a counterforce to the punch. Operators can select a die in a diverse variety of shapes for different bend angles.
- The backgauge is an adjustable stop that lets the operator accurately place the metal sheet. It ensures uniformity of all bent parts.
Press Brake Operation
Bending metal with a press brakes involves a range of steps.
- The operator selects the appropriate machine program from the system.
- The operator selects the correct punch and die based on design specifications.
- The operator places the metal sheet onto the bed of the machine and aligns with backgauge for accuracy.
- The metal sheet is clamped between the punch and the die and secured in place.
- The ram carries the punch downward and applies correct amount of force, which causes the metal to bend to the programed angular dimension.
- The ram retracts after desired bend angle is reached, and the clamp is released.
Recent Advances in Metal Forming
Advanced materials and smart technologies are among the trends impacting the metal forming process in today’s manufacturing.
- The growing use of advanced alloys including aluminum, titanium and carbon fiber composites help fabricators achieve lighter weight and improved performance. This is especially critical for applications demanding high strength-to-weight ratio. Specialized alloys also contribute to tailored properties like corrosion resistance and heat resistance.
- Many industries are seeing a strong push towards lighter components to meet sustainability and performance requirements, particularly in the automotive industry. This drives demand for lightweight alloys that reduce weight without compromising structural integrity.
- Increased adoption of automated systems and robotics let operators handle ever-more complex metal forming operations. Other benefits include improved precision, consistency and production speed.
- Integrated data analytics use sensors and IoT devices to monitor and optimize metal forming processes to improve speed, efficiency and quality control.
- Many industries are seeing a growing emphasis on environmentally friendly metal forming processes, including recycling and use of sustainable materials.
Get a Quote for Custom Metal Fabrication
If you need ready-to-install components for OEM manufactuing, get in touch with Metaltech to request a quote or schedule a tour of our facilities. Our family-owned company has met and exceeded customer expectations for 20 years and counting. You can also call us at 417-426-5577 or contact us online at any time.
