What is Sheet Metal Prototyping? Why is It Important?
A prototype in sheet metal fabrication is a physical model that allows designers to assess and evaluate the functionality and appearance of a part before mass production. Whether crafting functional prototypes or not, sheet metal offers a versatile medium for testing designs.
Not only does having a prototype attract more investor interest, showcasing the durability and aesthetics of the design, but transitioning from a sheet metal prototype to the final product is often more seamless than moving from a plastic prototype to a metal component.
Our Sheet Metal Prototyping Service Features
With two decades of metal fabrication experience, Tong Lay Doo pioneers innovation through advanced tools like laser cutting and computerized machinery to provide crucial custom metal fabrication prototype services. The process includes meticulous planning and setting the foundation for material selection and techniques.
Our client-focused approach allows for the fulfillment of low volume quantities and diverse needs, enabling visualization and testing to ensure the final products meet your precise requirements. This commitment to efficiency and precision helps introduce your products to the market swiftly, maintaining high quality and cost-effectiveness throughout the process.
Our Sheet Metal Rapid Prototyping Capabilities
At Tong Lay Doo, we understand the importance of quick turnaround times in the fast-paced world of product development. Our rapid prototyping services ensure that you receive your sheet metal prototypes within a standard lead time of just 7 business days. With a generous blank size of 10’ x 20’ (3.05 m x 6.10 m), we can accommodate larger part volumes upon request. Our sheet thickness options range from 0.024” to 0.250”, with the flexibility to meet requests for both thicker and thinner gauges.
We maintain precise tolerances to ensure the highest quality:
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For single planes or flat parts, we achieve a precision of +/- 0.010” on edge-to-edge, edge-to-hole, and hole-to-hole features, as well as +/- 0.010” on bend-to-edge/hole features.
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For multi-planed bent parts, our tolerances stand at +/- 0.030” for hole-to-hole/edge, edge-to-edge, and over-formed parts, with a bend angle tolerance of +/- 1 degree.
Following are the detailed processes and sheet metal forming methods we use in our sheet metal rapid prototyping capabilities, such as laser cutting, welding, etc, designed to deliver high-quality prototypes swiftly and efficiently.
Stamping
Stamping involves pressing sheet metal into the desired shape using a die. This method includes various processes such as punching, blanking, drawing, and embossing. It is ideal for creating complex parts with high precision and repeatability, making it suitable for large-scale production.
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Mass Production Lead Time: 1-15 days
CNC Punching
CNC punching employs a computer-controlled punching press to create holes and shapes in metal sheets. This technique is effective for producing parts with repetitive patterns and complex geometries, ensuring consistency and accuracy.
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Mass Production Lead Time: 1-15 days
Laser Cutting
Laser cutting uses a focused laser beam to precisely cut through metal sheets, allowing for intricate designs and accurate shapes. This method is highly efficient for both prototyping and mass production due to its precision and minimal material waste.
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Mass Production Lead Time: 1-15 days
Welding
Welding joins metal pieces together using heat and pressure to create strong and durable connections. This process is essential for assembling complex parts and structures, ensuring stability and longevity.
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Mass Production Lead Time: 1-15 days
Bending
Bending shapes metal sheets by applying force, often using a press brake, to achieve desired angles and forms. This method is crucial for forming parts with specific dimensions and angles, offering flexibility in design.
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Mass Production Lead Time: 1-15 days
Assembly & Kitting
Assembly involves putting together fabricated components, while kitting organizes them into kits for efficient use in the manufacturing process. This step ensures that all parts are correctly assembled and ready for final production or distribution.
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Mass Production Lead Time: 1-15 days
What to Consider When Designing for Rapid Sheet Metal Prototypes
Designing for rapid sheet metal prototypes involves specific considerations to ensure manufacturability, cost-efficiency, and structural integrity. By following best practices, you can streamline the production process and achieve high-quality results. Here are some great tips for you:
Maintain Constant Material Thickness
Maintain a uniform material thickness in your design to simplify manufacturing and reduce costs. While selectively thickening areas by welding multiple sheets is possible, it’s costly and uncommon. Ensure your design falls within our sheet metal thickness range to maintain structural integrity and manufacturability.
Use Universal Tooling
Design parts to use standard configurations of universal tools rather than part-specific tooling. This makes fabrication more economical. If a part is too complex, consider designing it in separate pieces to be welded or riveted together.
Follow Countersink Application Methods
When incorporating countersinks, determine whether a drill press or punch press tooling is more appropriate based on your part geometry. Drill presses are better for tight angles and hard-to-reach features, while punch press tooling is more efficient for accessible areas.
Factor in Generous Tolerances
Sheet metal tolerances are generally more generous than those for machining or 3D printing. Factors such as material thickness, the machines used, and the number of production steps all affect tolerances. Ensure you understand and design within these constraints.
Consider Press Brake Limitations
Since a press brake creates bends by pressing sheet metal into a die, it cannot create closed geometry. Design your parts accordingly to avoid issues during bending.
Our Material Options for Sheet Metal Prototyping
- Aluminum 5052, 6061
- Stainless steel 304, 316L
- Mild steel 1018
- Copper C110
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Our Prototype Sheet Metal Parts & Applications
Sheet metal prototyping is essential across various industries due to its versatility and durability in producing a wide range of fabricated parts.
In chassis construction, it allows for the creation of robust frameworks from materials like aluminum and stainless steel, essential for supporting technology in audio equipment, drones, and vehicles. For enclosures and housings, sheet metal fabrication offers durable, cost-effective protection for sensitive electrical equipment.
Custom designs can meet waterproof standards and include user interfaces for applications in remote-controlled machinery, and computer housings. This adaptability makes sheet metal prototyping a reliable solution for producing high-quality components in diverse fields.
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Contact us via the button below now enjoy our rapid custom sheet metal prototypes service!
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