Precision-Crafted Metal Solutions for Demanding Industries
Breaking the Cost-Delay Barrier in Custom Fabrication
Engineers face a universal dilemma: Need functional brass, aluminum, or steel prototypes fast? Traditional shops force 8-week waits and $15k setups for tiny batches. Our Custom Sheet Metal Fabrication methodology eliminates this through material-intelligent processes:
- Brass: Laser-cutting delicate circuits with ±0.05mm tolerance
- Aluminum: CNC punching thin enclosures (0.6mm) in 48hrs
- Steel: Automated bending of heavy brackets with zero tooling
Result: 68% faster delivery and 45% cost reduction vs. industry averages.
Industry Applications: Solving Low-Volume Nightmares
1. Aerospace & Defense
Problem: 12-week delays for certified thin-gauge aluminum sensor housings (MIL-SPEC compliant).
Solution:
- Al 6061-T6 laser cutting with argon shielding
- Deburring to Ra 0.4µm
- 20-unit batches in 7 days at $82/unit
2. Luxury Electronics
Problem: $250/unit for polished precision etched brass nameplates (qty: 50).
Solution:
- Chemical etching (0.2mm depth accuracy)
- Mirror finishing + anti-tarnish coating
- 50pc delivery: 5 days @ $110/unit
3. Industrial Robotics
Problem: 6-week minimum for low-cost steel brackets for robotics (±0.1mm flatness).
Solution:
- Adaptive press braking with real-time angle correction
- Powder-coating included
- 100pc batches: $6.50/unit (8 days)
4. Medical Devices
Problem: 10-week cycles for small-batch brass electrical contacts (ISO 13485 compliant).
Solution:
- Micro-turret punching (0.8mm C26000 brass)
- Passivation for biocompatibility
- Prototype 10pcs: 3 days | $95/unit
Material-Specific Process Intelligence
| Material | Optimal Techniques | Tolerance | Economical Batch |
|---|---|---|---|
| Brass | Photo etching, CNC piercing | ±0.03mm | 5-200 units |
| Aluminum | Fiber laser cutting, Nylon coining | ±0.07mm | 1-500 units |
| Steel | Plasma cutting, Robotic welding | ±0.12mm | 10-1000 units |
Key innovation: Our AI-driven Geometry Interpreter analyzes CAD files to auto-select processes:
- Complex curves → Laser cutting
- 90° bends <1.5mm → Air bending
- Micro-features → Chemical etching
Cost Compression Technologies
1. Digital Nesting 4.0
- Scrapless layouts for brass/aluminum sheets
- Savings: 32% material waste reduction
2. Instant Tooling Database
- 15,000+ in-stock punches/bends
- Effect: Zero setup fees for 83% of orders
3. Express Prototyping Line
- Dedicated to quick-turn aluminum EMI shields (1-50pcs)
- Fixed pricing: 320setup+12/part
Weekend Special (Expires July 13, 23:59 EST)
🔥 Orders confirmed tonight receive:
- FREE GD&T report ($550 value)
- 10% discount (Code: METAL24)
- Guaranteed 5-day delivery
[Upload CAD Now] | [Download Material Guide]
Case Study: Satellite Brass RF Shields
Client Challenge:
- 42 brass shields with 0.3mm cooling slots
- Traditional quote: 9 weeks | $28k