Metal fabrication is a cornerstone of modern manufacturing, and understanding its fundamental components is essential for planning a successful project. At EVS Metal, we pride ourselves on being experts in precision sheet metal fabrication, offering everything from single parts to fully assembled enclosures. Let’s break down the essential elements of metal fabrication—parts, weldments, and assemblies—and explore how they come together to create products that power industries.
Precision Fabricated Sheet Metal Parts
At the heart of every metal fabrication project is the individual sheet metal part. These parts are fabricated from stainless steel, aluminum, or other metals and can either stand alone as finished items or be combined into larger assemblies.
For example:
• Standalone Parts: Brackets, panels, and hinges that perform specific functions.
• Components in Assemblies: These parts can be welded or fastened together to form complex structures like cabinets or enclosures.
Each sheet metal part is crafted with precision to ensure it meets exact specifications, forming the foundation for weldments and assemblies.
Weldments: Strength in Unity
Weldments are the result of joining multiple metal parts together through welding processes like spot welding, arc welding, or TIG welding. These assemblies provide durability and structural integrity, making them essential for heavy-duty applications.
Examples of weldments include:
• Industrial Frames: Used in construction, such as structural steel supports.
• Enclosures: Custom-fabricated panels welded together to house sensitive equipment.
Weldments serve as intermediate structures that can be further enhanced with additional parts to create complex assemblies.
Metal Assemblies: The Big Picture
A metal assembly refers to the finished product that combines individual parts and weldments into a complete unit. Assemblies can range from simple products like brackets to intricate enclosures or machinery.
Key processes for creating assemblies include:
• Welding: For strong, permanent connections.
• Fastening or Riveting: When flexibility or modularity is needed.
• Adhesive Bonding: For specialized industrial applications.
Common examples:
• Server Racks and Cabinets: Used in IT and telecommunications industries.
• Medical Carts: Custom-designed for mobility and functionality in healthcare settings.
Assemblies are versatile and can be tailored to meet the needs of various industries, ensuring durability, functionality, and precision.
Key Components in Metal Fabrication
Brackets
Brackets are an extremely useful type of sheet metal part. Brackets can be fabricated in nearly any size, depending on the project’s requirements. Smaller brackets are used for products like enclosure shelves, while larger ones can be found in structural steel projects, such as those EVS Metal fabricated for the new Tappan Zee Bridge project in 2015.
Metal brackets also come in various shapes meant for specific purposes. Z-brackets, for instance, are generally used when mounting offset parallel surfaces within a metal enclosure. Gusset brackets, on the other hand, usually form a triangular shape, and are meant to supply additional strength and rigidity within a weldment or assembly. L-brackets are often used when it’s necessary to mount a vertical component to a horizontal surface (or horizontal components to vertical surfaces, for that matter), and are helpful for mounting shelves within an enclosure. Other common bracket types include offset brackets (similar to z-brackets) and u-brackets (used for mounting parallel surfaces together).
Metal Hinges
Metal hinges allow for movement between two parts of a metal assembly or finished product by allowing the two parts or surfaces to rotate around a fixed axis point. The most common type of hinges make it possible to open and close a door or lid, like those found on cabinets and boxes. A hinge can be fabricated out of both steel and aluminum, and the metal choice depends largely on the application. Aluminum is lighter, but not quite as strong as stainless steel, however, because it doesn’t rust, is a good choice for products that will get wet or are to be placed in humid locations. While steel can be used outside, it is not always the best choice for these projects. However, it is nearly always necessary to use steel for structural projects like bridges due to its strength, regardless of the environment.
Industrial Metal Supports
Metal supports are used for many applications, but this label tends to refer to structural steel parts used in construction. These can include beams, poles, certain types of brackets, pipes and tubes.
Commercial Metal Frames
Metal frames are a type of weldment and/or assembly. They are available in a wide range of sizes and types, depending on their intended use. Metal frames can be fabricated from structural steel for construction projects, or other industrial applications. However, smaller frames, like those for doorways, windows, shelving, or even assemblies like certain kinds of carts are all part of the frame category as well, and can be manufactured using metals like stainless steel or aluminum.
Fabricated Metal Arms
Metal arms can be manufactured from a combination of parts, weldments, or assemblies, depending on how complex they are. Fabricated arms include manipulating/manipulator arms, in vertical or horizontal orientations, with rocker or double-rocker suspensions. They can be powered by electric, pneumatic or hydraulic systems. Other types of arms include those for various types of lighting, from large industrial lights and architectural styles, to simpler desk lamps.
Fabricated Metal Lids and Covers
Metal lids are exactly what they sound like — a cover that fits over another object in order to seal, secure or close it. Garbage can lids, circular screw-top canister lids, metal fuse box covers, and metal cabinet doors are all types of lids.
Commercial Metal Panels
Sheet metal panels can be a confusing category, as the term is used to refer to two very different types of panels. There are architectural panels, which are primarily decorative in nature, and often used for commercial building projects, but the majority of fabricated metal panels are smaller and simpler than these. For instance, metal panels are often used to house electrical components when joined with other parts, such as covers and hinges. An excellent example of this is the common fuse box found in almost every electrified home and business.
Fabricated Metal Enclosures
Sheet metal enclosures are a huge category, and are the end-product of a nearly endless combination of parts, weldments and/or assemblies. They are most commonly fabricated from aluminum or stainless steel, and generally refer to commercial or industrial items. Examples of stainless steel and aluminum fabricated enclosures include cabinets, containers, cages, and even some types of carts, like those used to transport medical supplies between operating rooms. The main commonality is that all enclosures are designed to hold, store, or protect other, smaller items, from computer servers to commercial construction waste.
Metal Boxes
The term “metal box” is often used as a generic way to describe any sheet metal enclosure with 5 or 6 sides (the 6th being the addition of a cover, lid or door). They are manufactured from a variety of metals, like stainless steel and aluminum, and are available in any number of sizes. Box enclosures can be very simple, or much more complex when other parts are added. Examples of metal boxes include toolboxes, pull boxes, hinged boxes, and latch boxes.
Commercial Metal Cabinets
Metal cabinets are their most basic are simply metal boxes with doors attached, usually via a type of bracket and hinge, and are fabricated in a wide range of sizes. There are smaller cabinets, like metal surgical carts, that add wheels to allow them to be used to transport instruments, and large cabinets like school and gym lockers, which are stationary but add security measures like locks to secure valuables. Cabinets may contain inner racks, shelves, or drawers, depending on their intended use.
Industrial Metal Containers
A common type of commercial container are those used to transport goods via cargo ship over water and then by train overland. These are also called “dry” shipping containers. Other types of metal containers are storage and moving “pods.” Smaller types of containers are also available, and tend to be modular and or stackable for use as storage in warehouses and other similar environments.
Commercial Metal Bins
A metal bin is essentially a type of container, but they generally are not fitted with covers, which means they cannot be used to secure valuable items. They are used both indoors and out, for a wide variety of applications. Some common types of metal bins are those used to store and consolidate waste and/or transport materials on a construction job site. Although most bins are not used to store valuables, there are industrial bins available that feature covers and locks to store and protect large, expensive equipment that cannot be easily moved back and forth from day to day, like that which is used for long-term road work projects.
Smaller types of metal bins are also available, although generally meant for indoor use. These are used in commercial and industrial settings, in particular warehouses, and are often stackable to make the best use of space.
Streamlining the Fabrication Process
At EVS Metal, we aim to simplify the fabrication process for our clients. By offering a full range of services, we ensure that every step—from part fabrication to final assembly—is completed under one roof. This integrated approach provides several benefits:
• Precision and Quality: Every component is crafted and assembled with meticulous attention to detail.
• Efficiency: A streamlined process reduces production times and costs.
• Customization: Our team works closely with clients to create tailored solutions for their unique needs.
Why Choose EVS Metal?
As a trusted partner in precision sheet metal fabrication, we combine decades of expertise with cutting-edge technology to deliver exceptional results. Whether you need a single part or a complex assembly, we’re committed to providing high-quality solutions that meet the demands of your industry. Contact us at 1-888-9EVSMET or request a personalized quote online.
With locations in New Jersey, Texas, New Hampshire, and Pennsylvania, EVS is ready to bring your project to life. Let’s work together to create metal products that perform with precision, durability, and quality.