Sheet Metal Materials

sheet metal.jpg

Sheet Metal Fabrication materials

Pictures	Materials		Details
	Aluminum	Aluminum 6061	Our aluminum alloy. With good strength-to-weight ratio, excellent machinability and natural corrosion resistance.
	Aluminum	Aluminum 5052	The strain hardening aluminum alloy with excellent corrosion resistance. Suitable for marine applications. Can be welded.
	Stainless Steel	Stainless steel 304	The most common stainless steel. It is non-magnetic steel.
		Stainless steel 316/316L	SS316 has superior corrosion resistance in chloride containing environments, with good elevated temperature strength.
		Stainless steel 301	SS303 has excellent toughness, but lower corrosion resistance than 304
		Stainless steel 201	High density, with certain acid and alkali resistance, no bubbles, no pinholes.
	Copper	Copper	Good electrical conductivity, thermal conductivity, ductility, deep drawing and corrosion resistance.
	Mild steel	Mild stee 1018	Good machinability, weldability, toughness, strength, but it's susceptible to corrosion on the surface.

Choosing a Sheet Metal Grade

Sheet metal selection is driven by three things: what the part must survive, how it will be formed, and how it will be finished. The grade you pick determines all three.

Corrosion resistance. Indoor panels are fine in mild steel; outdoor, marine and wash-down parts call for 5052 aluminium or 304/316 stainless.
Formability. Parts with tight bends and deep draws need ductile grades. 5052 bends cleanly where harder tempers crack.
Weldability. Some grades weld beautifully, others are best joined with rivets or fasteners. Tell us the joining method up front.
Weight. Aluminium removes about two-thirds of the weight of an equivalent steel panel — decisive in anything that moves.
Finish. Mild steel needs paint or plating; aluminium can be anodised; stainless is often left bare or brushed.

Thickness, Bend Radius and Formability

Bending is where most sheet metal problems begin. The inner bend radius must be large enough for the material to stretch without cracking, and the minimum radius scales with thickness.

Material	Typical thickness	Minimum bend radius	Notes
Cold-rolled steel (SPCC)	0.5–3.0 mm	≈ 1 × thickness	Cheap and strong; must be painted
Galvanised steel (SGCC)	0.5–3.0 mm	≈ 1 × thickness	Zinc coating resists corrosion
Stainless 304	0.5–3.0 mm	≈ 1 × thickness	Harder to form; springs back
Aluminium 5052	0.8–4.0 mm	≈ 1 × thickness	Excellent formability and corrosion resistance
Aluminium 6061	0.8–4.0 mm	≈ 2–3 × thickness	Stronger but cracks on tight bends

Springback is a related issue: metal springs back slightly after the punch releases, so we over-bend to compensate. Harder materials spring back more, which is why stainless and 6061 need more allowance than mild steel.

Material Comparison for Fabrication

Cold-rolled steel — the economical default for brackets, chassis and enclosures that will be painted.
Galvanised steel — where corrosion resistance is needed without a paint line.
Stainless 304 — food equipment, medical carts and architectural parts.
Aluminium 5052 — the best all-round forming aluminium; aircraft panels, electronics chassis.
Aluminium 6061 — where strength matters more than tight bending.
Copper and brass — busbars, RF shielding and decorative parts.

Surface Options for Sheet Metal Parts

Finishing is chosen with the material, not after it. Powder coating gives a durable, thick, coloured finish on steel and aluminium. Anodising suits aluminium and preserves a metallic look. Zinc plating and passivation protect steel and stainless respectively. Brushing and bead blasting set the texture that the final finish sits on.

Frequently Asked Questions

What is the minimum bend radius I should design for?

A safe starting rule is one times the material thickness for mild steel and 5052 aluminium, and up to three times for 6061 aluminium. We will confirm the exact figure against your grade and temper.

Can you make a single sheet metal prototype?

Yes. One-off brackets and enclosures are routine, produced by laser cutting and press-brake forming without the tooling cost of stamping.

When does stamping become cheaper than fabrication?

Once volumes are high enough to amortise a hard tool — typically thousands of identical parts. Below that, cutting and forming is faster and cheaper overall.

Do you provide the flat pattern?

Yes, we generate the flat pattern and bend sequence from your 3D model so that the finished part matches the drawing after forming.