Introduction
In the process of converting raw materials into finished goods, a fabrication shop is very important. These shops offer services such as metal fabrication, sheet metal processing, and many others, which will help you make your parts, components, or structures. The process is very important in the current world of manufacturing since it helps to bring prototypes or production lines to life with accuracy and speed.
For companies that do not have the capacity or equipment, outsourcing to an expert fabrication shop guarantees quality work. You can be assured that the project will be completed to your specifications and on time since they have better tools and specialized knowledge. In this article, we will look at what fabrication shops are and what they provide and how you can select the best fabrication shop.
What Exactly is a Fabrication Shop?
As its name suggests, a fabrication shop is a place equipped with machinery, use of tools, and skilled workforce, transforms materials into finished or semi-finished products through using different processes of manufacturing. These are also known as “fab shop” or “job shop” and while most of them deal with metals, some may also work with plastics, composites and other materials. The most important aspect of a fabrication shop is the capability to manufacture parts or structures that are designed according to the client’s requirements.
Unlike mass production facilities that focus on high volumes of standardized items, fabrication shops usually work with few pieces but there is an exceptionally high level of customization. They are the link between the concept and the finished product, transforming drawings, CAD files and models, 3D models, or even simple sketches into a product through the use of technical skills and accuracy. You may also upload your own file for an entirely unique piece.
The size and the range of a fabrication shop can be anything from a small shop that offers only a few services to a large shop that offers a lot of services. In both cases, the goal remains the same, to offer customized manufacturing services to their clients depending on their needs. The kind of work that may be done can be as basic as cutting or as elaborate as assembly.
Key Services and Technologies Offered by Fabrication Shops
Fabrication shops provide a vast range of services, which may vary depending on the customer’s requirements and the field of activity. It is important to have this understanding when looking for a fabrication partner.
| Service | Process | Materials Used | Common Applications |
| Cutting | Laser Cutting, Plasma Cutting, Waterjet Cutting, Shearing | Metals (steel, aluminum), Composites | Sheet metal parts, automotive parts, signage |
| Bending | Press Brake Bending, Roll Bending | Sheet metal (steel, aluminum) | Frames, enclosures, brackets |
| Welding | MIG, TIG, Stick Welding | Steel, Aluminum, Stainless Steel | Automotive parts, structural components |
| Stamping | Blanking, Piercing, Forming | Sheet metal (steel, aluminum) | High-volume parts like washers, clips |
| Forming | Deep Drawing, Spinning, Rolling, Forging, Extrusion | Metals (steel, aluminum), Plastics | Complex shapes, custom parts, pipes |
| Machining | CNC Milling, CNC Turning, Drilling | Metals, Plastics | Precision components, engine parts |
| Finishing | Powder Coating, Plating, Polishing | Metal surfaces | Corrosion protection, aesthetic finishes |
Cutting
Cutting is a fundamental process in fabrication, involving the separation of material into desired sizes and shapes. Various methods are employed, each with its own advantages and applications, suited to different materials and thicknesses:
- Laser Cutting: Utilizes a high-powered laser beam to precisely cut materials. It offers high accuracy and clean cuts, suitable for intricate designs and a variety of materials.
- Plasma Cutting: Employs a high-velocity jet of ionized gas (plasma) to melt and expel material. It is effective for cutting thicker metals, particularly steel and aluminum.
- Waterjet Cutting: Uses a high-pressure jet of water, sometimes mixed with abrasive particles, to cut through a wide range of materials, including metal, stone, and composites. It produces no heat-affected zone, making it ideal for sensitive materials.
- Shearing: A mechanical process that uses opposing blades to cut sheet metal in a straight line. It is efficient for high-volume, straight cuts.
- Sawing: This is the process of cutting through various materials using a toothed blade, which is used in cutting bars, tubes and structural shapes. Some shops may also provide CNC routing to cut non-metal materials like wood and plastic as well.
Bending
Bending is the process of deforming materials to the required angles or curves by exerting force on them. This is widely used in a sheet metal fabrication process. And very important for the development of complex shapes and parts:
- Press Brake Bending: A specific type that employs either hydraulic or mechanical press in bending sheet metal using a punch and die setup which enables forming and angling with higher precision, often used in producing metal frames and parts.
- Roll Bending: In this type, metal is fed between a set of rollers that are rotated to produce a curve. This is common for pipes and tubes, as well as for large radius bends in sheet metal.
Bending is a critical process in the manufacturing of custom parts or components since it determines the material’s quality and the functionality of the final product.
Welding
Welding is a common joining process that melts two or more works of materials together including metals by heat, pressure, or a combination of both with the addition of a filler. Different operational techniques of welding are tailored to distinct materials and preferences:
- MIG Welding (Gas Metal Arc Welding – GMAW): This is a welding process that uses a continuously fed wire electrode and a shielding gas to produce the weld. It is general and widely used for most of the metals.
- TIG Welding (Gas Tungsten Arc Welding – GTAW): This is a process that uses a non-consumable electrode which is the tungsten electrode and a shielding gas to produce high quality and accurate welds, especially on metals such as aluminum and stainless steel.
- Stick Welding (Shielded Metal Arc Welding – SMAW): It uses an electrode wire that is covered with a flux that acts as both the shielding gas and the source of the filler metal. It is a flexible and mobile technique that can be applied in different fields.
Some of the other welding processes are flux-cored arc welding (FCAW) and submerged arc welding (SAW). The type of welding to be used depends on the type of material to be welded, the strength and appearance of the weld required and the project standards.
Stamping
Stamping is a manufacturing process that is used to emboss or impress designs on sheet metal. It refers to the process of feeding flat metal in the form of coil or blank into a stamping press where the tool and die surface shape the metal into the required form. Stamping is a high volume production process that is ideal for making many similar parts at a go. Some of the most common stamping processes include blanking, piercing, forming, and drawing.
Forming
Forming encompasses a range of processes used to shape metal without cutting or joining. Besides bending and stamping, this can include:
- Deep Drawing: A process used to form cup-shaped or box-shaped parts from sheet metal by forcing a punch into a die.
- Spinning: A process where a disc or tube of metal is rotated at high speed and formed into an axially symmetric part by applying pressure with a tool.
- Rolling: A process where metal is passed between one or more pairs of rolls to reduce its thickness, change its cross-section, or improve its surface finish.
- Forging: A manufacturing process involving the shaping of metal using compressive forces. These forces are applied with a hammer or die.
- Extrusion: A process where a material is pushed through a die of the desired cross-section. This forces the material to take the shape of the die opening.
Machining
While fabrication shops primarily focus on shaping and joining, many also offer machining services to achieve precise dimensions and finishes. Common machining processes include:
- CNC Milling: Uses rotating cutting tools controlled by computer numerical control (CNC) to remove material from a workpiece.
- CNC Turning: Involves rotating a workpiece while a stationary cutting tool removes material to create cylindrical shapes.
- Drilling: Creates holes in materials using rotating drill bits.
- Grinding: An abrasive machining process that uses a grinding wheel to remove material from a workpiece.
CNC machining involves the use of computers to control the motion of the cutting tools, and it is accurate and consistent. Machining is usually applied to produce intricate shapes and dimensions that are difficult to achieve through other processes.
Finishing
After the fabrication process is done, there is a need to apply finishing to enhance the appearance, corrosion resistance or any other desirable characteristics of the final product and this can be done through:
- Painting: Applying a coating of paint for aesthetic purposes and protection.
- Powder Coating: Spraying a dry powder through an electrostatic process and then heating it to add a durable finish.
- Plating (for example, electroplating, anodizing): The process of depositing a layer of metal on the surface of another metal by passing an electric current through an electrolyte solution.
- Galvanizing: The process of coating steel or iron with zinc to avoid rust formation on the surface of the material.
- Polishing and Buffing: The processes of making the surface of the metal smooth and shiny.
The specific finishing requirements vary depending on the intended use of the product and the conditions in which it will be used.
Diverse Applications of Fabrication Shops
The capabilities of fabrication shops are reflected in the fact that they can be used in a wide range of applications in various industries:
Automotive Industry
Fabrication shops are very important in the automotive industry as they manufacture various parts such as chassis, body, exhaust systems, brackets and interior structures. Due to the need for accuracy, strength, and frequently large quantities, fabrication shops are valuable allies for the automotive industry.
Aerospace and Aviation
The fabrication shops are essential in the aerospace and aviation industries since they provide structural parts for aircraft, engine parts, landing gears, and interior fittings. These applications require a high degree of accuracy, material quality, and compliance to safety requirements. Companies operating in this sector tend to use materials such as aluminum alloys and titanium which are light but strong.
Construction and Infrastructure
Fabrication shops such as metal fabrication shops are crucial to the construction and infrastructure industries as they provide structural steel for buildings, bridges, and other large-scale projects. They also manufacture parts such as railings, stairs, platforms and other custom metal works for architectural purposes. One of the most important aspects of fabrication shops in this industry is their capability to build large structures of high strength and durability to the required specifications.
Electronics and Technology
The electronics and technology industries use fabrication shops for the fabrication of enclosures for electronics gadgets, chassis for servers and computers, heat sinks, and other precision metal parts used in electronics assemblies. The need for miniaturization and complex shapes means that fabrication shops need to have high levels of precision in machining and sheet metal work.
Medical Devices and Equipment
Fabrication shops are an essential part of the medical device and equipment industry since they provide surgical instruments, medical device casings, hospital furniture, and components of diagnostic equipment. This sector requires high standards of cleanliness, material compatibility and compliance with stringent regulatory standards.
Energy Sector
Fabrication shops provide products for the energy industry in the form of parts for power plants, oil rigs, and equipment for renewable energy such as windmills and solar panels. This can include large structural members, pipes and ducts, and other large containers.
What Drives Fabrication Shop Cost?
It is important to know the factors that affect the cost of fabrication services so as to plan and budget appropriately. Most shops have instant price quote tools like the parts builder and part templates to enable you to get an estimate of the prices. It is advisable to check the current prices because the cost of the materials may change from time to time. The following are some of the factors that determine the final price:
Material Costs
The nature and amount of material needed for a project are some of the cost drivers that are likely to affect the cost of the project. The cost of steel, aluminum, stainless steel, brass and other metals may vary depending on the market forces of demand and supply. Certified or specific alloys or materials will also affect the cost of the product.
Complexity of the Project
The intricacy of the design, including the number of parts, the tightness of tolerances, and the complexity of the required shapes, will directly affect the labor and machine time involved, thus influencing the cost.
Manufacturing Processes Involved
The specific fabrication processes required for a project will impact the cost. For instance, laser cutting typically costs between $0.10 to $0.50 per inch, while precision welding rates may range from $80 to $150 per hour. More basic processes, like shearing, tend to be less expensive, averaging around $50 to $75 per hour. Additionally, you can request instant pricing based on the number of different processes needed, which will also contribute to the overall expense.
Volume of Production
The quantity of parts being fabricated can significantly impact the per-unit cost. Higher volumes often allow for more efficient production methods and potential discounts on materials, leading to lower unit costs. Conversely, small-batch or one-off projects may have higher per-unit costs due to setup times and specialized handling.
Lead Time and Urgency
Projects with tight deadlines or requiring expedited service may incur additional costs. Rushed production often necessitates overtime labor and potentially disrupts the shop’s regular schedule.
Finishing Requirements
The type and extent of finishing required will affect the final cost. Simple cleaning and deburring will be less expensive than complex painting, powder coating, or plating processes. Specific surface finish requirements can also add to the expense.
Labor
Labor costs play a significant role, especially with skilled personnel. For example, a welder’s hourly wage might range from $18 to $35, while engineers and machinists can command $40 to $100 per hour, depending on expertise. Highly specialized workers can push costs even higher.
Overhead
Fabrication shops have various overhead costs, including rent, utilities, equipment maintenance, insurance, and administrative expenses. These costs are factored into their pricing structure.
How to Choose the Right Fabrication Shop?
Selecting the appropriate fabrication shop is critical for the success of your project. Following best practices in your selection process will save you time and money in the long run. Several factors should be carefully considered during the decision-making process.
Communication and Service
Effective communication is paramount. A good fabrication shop will be responsive, clearly understand your requirements, and provide regular updates on the project’s progress, ensuring the delivery of a quality product. Their customer service should be professional and helpful throughout the entire process.
Area of Expertise
Different fabrication shops may specialize in specific materials, processes, or industries. Ensure that the shop you choose has the necessary expertise and experience relevant to your project’s requirements. For instance, if your project involves intricate sheet metal components, a shop specializing in sheet metal fabrication with advanced bending and cutting capabilities would be a suitable choice.
Experience
A fabrication shop with a proven track record and years of experience is generally a safer bet. Their experience often translates to a deeper understanding of potential challenges and the ability to deliver high-quality results consistently. Review their portfolio and ask for references to gauge their capabilities.
Industry Standards
Ensure that the fabrication shop adheres to relevant industry standards and certifications like ISO. This is particularly important for projects in highly regulated industries like aerospace, automotive, and medical devices. Compliance with standards ensures quality and safety.
Partner with a Reliable Fabrication Shop
Choosing the right fabrication partner is an investment in your project’s success. At TZR, with over two decades of experience in the sheet metal fabrication industry, we provide end-to-end sheet metal solutions for industries like automotive, medical, 3D printing, and renewable energy.
Our expertise in handling materials such as steel, stainless steel, aluminum, and copper allows us to offer services from design and prototyping to mass production. Our advanced 11,000 sqm facility, equipped with cutting-edge machinery like 20,000W laser cutters and automated bending arms, ensures precision and efficiency in every project.
With competitive pricing for both small and large-scale orders, we can meet tight deadlines—delivering within 7-20 days. Our commitment to ISO 9000 standards and a 98% product quality pass rate guarantees that your project will meet global standards. Partner with TZR for fast, cost-effective, and reliable sheet metal solutions.
