Thursday, November 5, 2015

Aluminum Sheet Metal Fabrication

After doing a design check in cardboard - which helped me realize I needed to add holes opposite my tabs - I am ready to fabricate in sheet aluminum.  I am using a softer aluminum sheet which I found on amazon, here.


I begin just as I did with my cardboard model - spray mounting the flat pattern I printed from Autodesk Inventor onto an appropriately sized piece of aluminum.



Next, I prepare for drilling by center punching all of my holes...



The divot left by the center punch will help guide the drill bit into the center.


I also do the same for all of the inner-corners of the design - I will be drilling holes here as well to aid in cutting the pattern out later.




For the next series of steps, I always make sure to protect my eyes.  Tiny bits of aluminum flying into my corneas does not sound like a particularly pleasant experience...



I start by drilling every place I marked with the center punch (holes and corners)... and for this step I use a drill bit JUST under 2mm in diameter.  Shortly, I'll re-drill some of these holes with a bit that is slightly LARGER than 2mm...


With the <2mm bit, I drill each hole.





Next, I come back in with the >2mm bit, and re-drill the holes that my fasterner hardware (M2 bolts) will go through... but I leave the opposite holes (for me those are the ones on my tabs) small, so that M2 (2mm) bolts will actually thread into them.



Pictured above is a demonstration of what I'm talking about... the larger holes (on the right) allow to screws to pass through, while the smaller holes (on the left) require the bolt to actually thread into the aluminum.  This way, I shouldn't need to use any nuts to hold the bolts in place.


You will find, when drilling aluminum with a standard drill bit, that you get a pretty nasty burr on the opposite side you drilled...



I like to clean these off with a countersink bit.  By just touching it down onto each hole, I can quickly remove the burrs.


Here I am very careful not to go too deep with the countersink bit, or I could bore out the holes I just carefully drilled.



I also like to pre-thread my bolts into each of the smaller holes... this will make it easier to screw into them during the final assembly.



With the holes drilled, I am ready to begin cutting.  I start with a tin snips for the simple straight cuts.


The holes I drilled at the inner-corners give me a place to terminate my cuts at...


Snip!




For finer detailed cuts, or intricate interior cuts, I use a jeweler's saw.


Which, if used properly, will cut through this aluminum like butter.


With the cuts complete, I am ready to score my bend lines.



For this, I'll be using a high-speed rotary tool / flex shaft and a cut-off disc.  I like to protect my face for this, since the rotary tool with likely be shooting bits of aluminum in my direction...

I also like to wear a work glove so I don't have to worry about "scoring" my knuckles...


I always start by scoring a scrap of aluminum, to get a good feel for how deep I should score my actual piece.




Adding these score lines will be essential, as they will allow for very tight bends.



I like to use a piece of angle-steel as a straight-edge for scoring...


Here is a video demonstrating this process:





With the scoring done, I am ready to bend.


Thanks to the score lines, I can do many of the bends by hand. But for the smaller incricate bends, it can be helpful to use a pliers.  I often use regular needle-nose pliers, but I cover the knurled surface with gaffer's tape to avoid scratching up the surface of my aluminum as I bend it...



Then I bend over each score line, little by little - going slowly with as much control as possible to avoid breaking the aluminum at the folds.


Once folded, I use M2 bolts to fasten each tab.  Here, the bolts go through the holes in the surface, then thread into the smaller holes in the tabs.





Done!


I used this same method to create my other design, as well...





To make it look more like the original surface model (above) I used my DIY hydraulic press to force it into shape...

A video posted by Bryan J Cera (@cera.tops) on


And finally, my sheet metal object is complete!

103 comments:

  1. That is Very really great Nice Blog Post, Thanks for sharing this intersting and very informative content. Always keep sharing.

    Sheet metal manufacturing company faridabad

    ReplyDelete
  2. I've never seen scoring done to aid in making sharp bends - that's a nice trick!

    Concord Sheet Metal

    ReplyDelete
  3. Hey bud, I love this. The precision put into making these objects. Seeing the process in such a visual way is really impressive and really makes you think about the effort that goes into even the simplest of fabrication projects. You must have a lot of patience. I don't think there's anyway I could do anything like that.

    ReplyDelete
  4. Great Share!

    Sheet metal is nothing but the flat, rectangular shape of the metal that can be used for various applications. There are several kinds of sheet metal fabrication services in the market today that provide a one stop destination for almost all conceivable requirements that an individual or industry may have.
    By the way, The things you people covered through the post are very informative. Keep sharing stuff like this.

    Thanks and regards
    Clinton Aluminum

    ReplyDelete
  5. Waw really Best Fabrication sheet metal Blog Post, Thanks for plesse sharing this intersting and very informative content. Always keep sharing.
    sheet metal industries faridabad

    ReplyDelete
  6. Wow wanderfull Best sheet metal Blog Post, Thanks for plesse sharing this intersting and very informative content. Always keep sharing.

    sheet metal industries faridabad

    ReplyDelete
  7. Nice and helpful tutorial,thanks for sharing it.I discovered it while searching about Aluminium sheet suppliers UK

    ReplyDelete
  8. Thank you for posting the great content……I found it quiet interesting, hopefully you will keep posting such blogs.

    Aluminum Kick Plate
    Aluminum Sheet Metal for Sale

    ReplyDelete
  9. This sheet matal your Blog post is very Nice and useful. Thank you fro sharing the infromation .

    sheet metal industries faridabad

    ReplyDelete
  10. Wow nice and great sheet metal post. Thanku share this post

    sheet metal manufacturer gurgaon

    ReplyDelete
  11. fantastic sheet metal and useful your Blog post.Thank you for sharing this infromation.

    sheet metal manufacturing companies noida

    ReplyDelete
  12. I like it your blog post This really great information and usefull post. Thanku plesse share this post.

    sheet metal industries faridabad

    ReplyDelete
  13. Thanks, Duroshox is pioneer Metal Fabrication Company in India providing wide variety of Sheet metal fabrication and known for their high quality and durability. Sheet metal fabrication

    ReplyDelete
  14. Wow wonderful post good imfromation. Thanku share this post.

    sheet metal manufacturing companies gurgaon

    ReplyDelete
  15. I like this post.better usefull post .thanks for share this posting.

    sheet metal manufacturer gurgaon

    ReplyDelete
  16. Fantastic your blog post. i like it good information and usefull post. Thanku plesse share this post.

    sheet metal industries faridabad

    ReplyDelete
  17. You have shared a nice blog and I am very much happy to read it.
    Aluminium plate

    ReplyDelete
  18. Your blog explaining all the main points very awesomely. Thanks for sharing this knowledgeable post. Visit: Laserschneiden

    ReplyDelete
  19. Your ideas are very useful. Actually one of my friends is planning to work in this field, so I’ll definitely recommend your post to him. used sheet metal equipment

    ReplyDelete
  20. I learn some new stuff from it too, thanks for sharing your information.
    אלומיניום

    ReplyDelete
  21. Use of aluminium does not limit or a particular industry only. But its multiple uses are making it more popular to many other industries as well. In last few decades steel industry has witnessed many changes brought by precision sheet metal fabrication manufacturer.

    ReplyDelete
  22. Sheet metal is nothing but the flat, rectangular shape of the metal that can be used for various applications. Really nice. thanks for sharing. Steel Suppliers in Chennai  provides best steel materials.

    ReplyDelete
  23. Good blog...Helpful information...This online store has many products for metal fabrication...Try this https://goo.gl/9HDCts

    ReplyDelete
  24. Really Great work... Only some of the famous Aluminum Name Plate Manufacturer produce these types of products with smart work.

    ReplyDelete
  25. metal roofing sheets

    Offering you a complete choice of products which include shade.

    Thank you

    ReplyDelete
  26. Shaktiman Packaging Pvt. Ltd. is one of the best Aluminum Tape Suppliers. We work according to the requirements and that’s why we offer a superior quality range of Aluminum Tape to the customers.

    ReplyDelete
  27. Wonderful blog post.
    I will really appreciate your blog.
    Thanks for share it.
    fabrication companies in abu dhabi

    ReplyDelete
  28. This comment has been removed by the author.

    ReplyDelete
  29. I discovered this kind of large amount of fascinating stuff in your online journal particularly its discourse. From the huge amounts of remarks on your articles, I figure I'm not by any means the only one having all of the pleasure here! keep doing awesome…steel buildings essex

    ReplyDelete
  30. Great execution of work with the help of paper drawing and work done perfectly, as i saw in your post that your first priority is safety, big appreciation for that. Keep it up.

    Thank you!

    aluminium roofing sheets

    ReplyDelete
  31. I am regular reader of your blog and no doubt it all stuff is awesome. The best thing about your sharing and posting is that you always provide content that is helpful for both the newbie and experts.
    Aluminium Fabrication in India
    Stainless Steel Fabrication in India

    ReplyDelete
  32. Hi, Nice post.
    Thanks for sharing great post. Keep continue.

    ReplyDelete
  33. This is such a great resource that you are providing and you it away for free. I love seeing blog that understand the value.
    Stainless Steel Sheets Manufacturers in India

    ReplyDelete
  34. hey,bryan cera love the information about aluminium sheet metal fabrication,great elaboration of every image and its explanation,for more information on such do visit:
    febricators in nagpur

    ReplyDelete
  35. Very nice post. it is very useful and informative post. thank you for your sharing.
    ACP Work in Chennai
    MS Fabricators in Chennai

    ReplyDelete
  36. Your question makes no sense- you do not get foot pegs welded to a sissy bar. And you should not get a sissy bar welded to a fender bracket- it should be bolted onto tabs welded to the fender bracket.

    automation canada

    ReplyDelete
  37. Nice blog..! I really loved reading through this article. Thanks for sharing such a amazing post with us and keep blogging..
    Fabrication Vadodara
    Engineering Services Navimumbai

    ReplyDelete
  38. Hi, This is the best blog thank you so much for this better information.
    Here i am giving you best services of Aluminum Sheets Suppliers in Delhi NCR.

    ReplyDelete
  39. Thanks for sharing wonderful fabricator ideas and design with us.if you are searching for best fabricator services then visit site:Best fabricator in Nagpur

    ReplyDelete
  40. Well description with good images about metal fabrication. We are providing Heavy Steel Fabrication in India

    ReplyDelete
  41. This comment has been removed by the author.

    ReplyDelete
  42. Thanks for the article; it is very useful and great information. Thanks for the blog
    click here

    ReplyDelete
  43. Hello.
    This is the great blog to get a lot of information.
    Thank you so much.
    fabrication companies in abu dhabi

    ReplyDelete
  44. Great piece of writing, I really liked the way you highlighted some really important and significant points. Thanks so much, I appreciate your work. precision machine fabrication

    ReplyDelete
  45. Pretty nice post. I just stumbled upon your weblog and wanted to say that I have really enjoyed browsing your blog posts. After all I will be subscribing to your rss feed and I hope you write again soon! electrical engineering edmonton

    ReplyDelete
  46. First of all! I want to say thanks for your post because you have provided a better skilled welder. I am very interested in your post. Thanks for sharing this interested post for all peoples like me.

    https://otahuhuengineering.co.nz/

    ReplyDelete
  47. I have been looking for Metal Fabrication Company Alabama and fortunately, I read your blog that had brilliant Steel Cutting services performed by Browning Inc. I immediately contacted them through their website. I filled the form and they replied back to my query. They explained to me well the entire procedure for the Steel Fabrication. Since my work needed Steel Banding Services too, they were prompt to get my work done in this section also. The staff was extremely helpful in giving information about my work. I’m happy to deal with Browning Enterprise Inc as I got what I desired. Thank You for your blog information.

    ReplyDelete
  48. Good article you shared with us and I have enjoyed reading this article very much. Write such blogs. Thanks for sharing such a great post. https://www.invilfab.co.nz/

    ReplyDelete
  49. Hi, I'm an aluminum supplier from China, Shall we keep connection on aluminum alloy technology, you can also find the product i can supply on our website: https://www.aluminum-alloy-price.com
    PhoneNumber: +86-1-590-3641-529

    ReplyDelete
  50. I love by reading this blog.Very useful information about the aluminium sheet.jsw steel dealers in Chennaioffers a best standard and used for various purposes. The quality steels will be used in a wide range. The quality will earn the customer trust so they will refer a new customers.

    ReplyDelete
  51. This comment has been removed by the author.

    ReplyDelete
  52. Nice post. Thanks for sharing such type of valuable article. Keep sharing this type of informative post.I just want to tell you about Metals and Minerals products, equipments & materials which is also helpful . Thank

    ReplyDelete
  53. I have been looking for Metal Fabrication Company Alabama and fortunately, I read your blog that had brilliant Steel Cutting services performed by Browning Inc. I immediately contacted them through their website. I filled the form and they replied back to my query. They explained to me well the entire procedure for the Steel Fabrication. Since my work needed Steel Banding Services too, they were prompt to get my work done in this section also. The staff was extremely helpful in giving information about my work. I’m happy to deal with Browning Enterprise Inc as I got what I desired. Thank You for your blog information.

    ReplyDelete
  54. steel plate fabrication: I am happy to connect with Browning Enterprises Inc. They did the Steel Plate Fabrication process. They used quality steel products and exemplary on-time services.

    ReplyDelete
  55. Thanks for sharing the post. Select the good steel supplier.The best Steel Suppliers in chennai will support us to grow. The quality is the main thing to construct a building. Then also the quality of Steel Dealers in Chennai will satisfy the customer needs.

    ReplyDelete
  56. Excellent & informative post on Aluminum Sheet Metal fabrication. Get the best sheet metal fabrication services in Illinois from F.N Smith Corporation.

    ReplyDelete
  57. The process is very important for this is where the quality as well as the performance of the metallic pieces will improve. This application is also very necessary because it is cost efficient and inexpensive. There are actually 3 types of burrs generated from the operations namely Poisson burr, rollover burr and the breakout burr. The most frequent burrs is the rollover. sheet metal manufacturing process

    ReplyDelete
  58. As one of the leading web design agency , we understand that every client has a unique set of requirements that can be in the form of either generating leads, increasing sales or boosting traffic.
    Sheet Metal Contractor Website Design

    ReplyDelete
  59. I just got to this amazing site not long ago. I was actually captured with the piece of resources you have got here. Big thumbs up for making such wonderful blog page!. Fire Protection Services in bangalore

    ReplyDelete
  60. Thanks for sharing your post, this is really informative for me. It will help me in future, i appreciate your blog!! You can Also visit on..
    Robotic Automation in India | Gantry Robots |Special Purpose machine

    ReplyDelete
  61. Its a very nice blog post I found so much valuble information from this post. Keep continue to update a kind of information in Future in your blog. We are also in a same kind of business please visit the url to know more about us - steel fabrication company alabama.

    ReplyDelete
  62. Wow! Such an amazing and helpful post this is. I really really love it. It's so good and so awesome. I am just amazed. I hope that you continue to do your
    work like this in the future also. If you want leads for Refrigerator repair in Delhi visit our website now.

    ReplyDelete

  63. Hey, Nice post on SEO. The blog is so much informational it is very nice for us.
    AC repair service near me

    ReplyDelete
  64. Amazing blog post. thank you for sharing great knowledge.

    Pre Engineered Building.

    ReplyDelete
  65. Mittal Engineering is a Best Copper Coils Manufacturer in India. We use the best raw material to produce these Coils. As per the client’s needs, we are manufacturing and supplying customized as well as customized Coils. We are making the best quality of Copper Coils at affordable rates. We also Provide Copper Sheet, Copper Strips, Copper Circle, Brass Coils, Brass Sheet, Brass Circle these products at market affordable price.

    ReplyDelete
  66. This is the kind of blog I was looking from a long time, keep sharing such updates.
    Metal Finishing companies UK

    ReplyDelete
  67. Really very impressive blog about Aluminium sheet metal Fabrication.

    ReplyDelete
  68. Wow!! I am very impressed with your lovely post.. I am so glad to left comment on this.. This has been a so interesting read, would love to read more here…. Aluminium Sheet Metal Fabrication Very good Content You provide . if anyone looking for Metal Fabrication ERP Software

    ReplyDelete
  69. your blog is really amazing keep sharing this kind of useful information with us and check out our web portal Etisalat Yellowpages UAE for Aluminium Fabricators

    ReplyDelete
  70. ‘Mtek Sourcing ‘ is one such bridging company in India for sheet metal fabrication manufacturers which promises high quality metal, designing and services to their customers.

    ReplyDelete
  71. Excel In Your Exams With Our Expert Test Preparation Services! At Sistem Tutoring, We Offer Tailored Solutions Through Both In-Person Tutoring And Virtual Tutoring Sessions. Our Experienced Tutors Provide Personalized Guidance, Ensuring You Grasp Key Concepts And Ace Your Tests. Choose The Flexibility Of Virtual Tutoring Or The Traditional Approach Of In-Person Sessions For Effective And Comprehensive Test Preparation. Elevate Your Academic Success With Our Dedicated Tutoring Support

    ReplyDelete
  72. Malabou - Your Trusted Steel Fabrication Supplier in NZ!

    Welcome to Malabou, the leading Steel Fabrication suppliers in NZ ! As a trusted name in the industry, we offer top-quality steel products for all your construction and manufacturing needs. Our team of skilled professionals ensures precision and excellence in every project, delivering custom solutions that exceed expectations.

    With years of experience, we pride ourselves on delivering outstanding customer service and tailored solutions to meet your unique requirements. From structural steel and metal fabrication to welding services and more, we've got you covered. Trust Malabou for superior quality, value, and reliability in steel fabrication in NZ. Contact us today!

    ReplyDelete
  73. Aluminum extrusions are known for their exceptional properties that distinguish them. Their lightweight quality ensures easy handling and installation, highlighting their versatility across various industries. Additionally, their impressive durability makes them a reliable choice for sectors such as construction and automotive. These extrusions excel in their corrosion-resistant features, ensuring long-lasting performance in a diverse range of applications. Explore the wide selection of aluminum extrusions available today to find the perfect solution tailored to your specific needs and preferences!

    ReplyDelete
  74. Royal Allied offers Copper pipe repair in the UAE.We have experienced technicians who are skilled in diagnosing and repairing various types of pipe damage.

    ReplyDelete
  75. Leading providers of aluminium products in the United Arab Emirates, providing an extensive selection of aluminium wires, foils, sheets, rods, plates, tubes, pipes, and much more.

    ReplyDelete
  76. The greatest architectural engineering services from the UAE may be obtained by making an appointment with ATNINFO, the top architectural engineering consultants in Dubai, Abu Dhabi, and Sharjah.

    ReplyDelete
  77. Leading Door Hardware Architectural Supplier in Dubai, United Arab Emirates, Atninfo offers affordable prices. Purchase Door Hardware Online in Dubai, United Arab Emirates, at Best Prices.

    ReplyDelete
  78. Thankyu for sharing such as Informative blog. Your blog is really amazing keep sharing this kind of useful information with us and check out our website.
    metal fabrications brendale

    ReplyDelete
  79. Great blog on Aluminum Sheet Metal Fabrication! Your insights are incredibly detailed and useful. As a leading Sheet Metal Screw Supplier In Delhi , Nut Bolt Fit Well appreciates the in-depth information you've shared. This will surely help us enhance our understanding and service offerings. Keep up the excellent work!

    ReplyDelete
  80. Innovative Tools for Modern Public Safety Challenges

    Ensure public safety with cutting-edge tools designed for modern challenges. Explore innovative solutions that enhance security and efficiency in urban environments.

    ReplyDelete
  81. Thanks for sharing informative information on this blog! For anyone interested in top-notch steel services, check out a leading Steel Fabrication Company in Abu Dhabi. we offer exceptional quality and expertise for all your fabrication needs in the UAE. Contact us { +971 0563745538} For more information.

    ReplyDelete
  82. Thanks for sharing this valuable information about aluminium fabricators. If you want to explore more term related to metal fabrications, then must visit https://chanceymetals.com/. We offer metal, steel and aluminium fabrications services at reasonable price. To get in touch with us: 904.260.6880

    ReplyDelete

  83. Nurses' job vacancies in the UK are rapidly increasing, reflecting the urgent need for skilled healthcare professionals in diverse settings. Opportunities are available in hospitals, community health services, and care facilities, covering various specialties, including adult care, pediatrics, and mental health. Employers are offering competitive salaries, attractive benefits, and flexible working hours to entice qualified candidates. Many organizations also emphasize career development, providing training programs and pathways for advancement. International nurses are encouraged to apply, with assistance for visa processing and integration into the UK healthcare system. Recruitment agencies and job portals streamline the application process, connecting nurses with suitable positions. If you're passionate about making a difference in patient care, explore the many nursing job vacancies in the UK and take the next step in your career!
    https://www.dynamichealthstaff.com/nurses-job-vacancy-in-uk





    ReplyDelete
  84. UN certified bags! provide clear labeling for hazardous contents, promoting safety during handling. This feature helps prevent accidents and ensures that employees are aware of the materials they are working with.

    ReplyDelete