This is a design philosophy that encourages the client and the fabrication team to work together to ensure that project requirements are met in the most efficient, cost-effective way possible. Part design, resources, and manufacturing capabilities are all weighed in the DFM process.

Quality standards, special client requirements, and project quantities also matter in DFM. The key factors to consider include:

• Part specifications
• Material requirements
• Environmental compliance
• Quality assessment and testing

Metal stamping is typically used as “catch-all” term that includes a wide range of metal-forming operations – not just stamping, but also bending, folding, stretching, and pressing. In a metal stamping process, custom-made tooling and dies are fitted to punch presses to produce the exact shapes required for the parts being produced. The chief advantage of metal stamping is that it can quickly produce large quantities of cost-effective metal parts. Tolerances in metal stamping are typically tighter than in metal fabrication.

Metal fabrication uses an even wider variety of tools and techniques to create three-dimensional metal parts. More specialized equipment is used, such as CNC laser cutters, welding machines, CNC turret presses, and CNC press brakes. Metal fabrication can be the more cost-effective option for producing metal parts in smaller numbers; the tooling required for stamping can be prohibitively expensive for small production runs. Metal fabrication is also a more flexible process. Because there is no tooling to replace, part designs can be altered with minimal delay and expense.

A CNC punch press uses a variety of different tools to cut or punch custom shapes out of sheet metal. The “CNC” attached to the name indicates the machine is directly controlled by computer; it stands for “Computer Numerical Controlled.” A CNC turret punch press is a very versatile machine because it can handle an exceptional number of forming operations, including countersinking, embossing, tapping, bends, lances, knockouts, and more. Bayview Metals uses industry-leading CNC presses produced by Amada. The turrets on Bayview’s presses include 58 different stations and can punch cuts anywhere between 0.040″ and 4.500″.

As in the above discussion of CNC turret punch presses, CNC (Computer Numerical Control) technology adds complete computer oversight to the operation of the press brake. Software programming and digital design files dictate all of the machine’s activity. PLC controllers track all of the variables of production and ensure that every operation is highly repeatable and consistent. On a CNC press brake, every meaningful variable – including pressure, die selection, and back gauge settings – is controlled digitally rather than manually.

The primary benefits of custom sheet metal fabrication are:

• Complete freedom to create unique designs in any size.
• Effective and total quality control, including shapes, measurements, and dimensional tolerances.
• A custom fabrication delivers great value by supplying parts built expressly for the job at hand, with no adjustments required.
• Partnership with a professional fabrication company gives the client full control over every part of the fabrication process.
• Close coordination can produce parts very quickly.
• Custom fabrication can create more durable parts exactly suited to the environment they’ll be used — resistant to temperature, stress, vibration, chemicals, etc.

A press brake permanently reshapes sheet metal by forming bends over different dies and punches. Bend size is controlled with back gauges, while the punches and dies themselves determine the angles and radii of the bends.