As a manufacturer, you know that the manufacturing process behind your components makes a big difference in the quality of the product.
But with all of the different metal parts manufacturing methods available today, it can be difficult to determine which one is best for your needs. Different processes offer diverse benefits and capabilities and there is no “one-size-fits-all” solution.
Understanding the applications for different types of metal manufacturing will help you choose the best one for your metal components.
Here’s a look at the pros and cons of four main metal parts manufacturing processes used today:
Each metal-forming method has distinct advantages and disadvantages, so choosing the best service for your application will rely on several factors. including (but certainly not limited to):
Each of the previously mentioned metal parts manufacturing methods will perform differently for each factor.
Choosing a metal manufacturing company begins with knowing what they can produce. Here are the advantages and disadvantages of the four primary production methods used by metal manufacturers:
Roll forming involves gradually bending flat sheet metal into a longitudinal, uniform profile by passing it through a series of mated tool dies.
Roll forming tooling costs may be higher when compared to other forming services, but roll forming allows for more in-line fabrication, medium to large runs, and higher volume orders.
Due to the more gradual forming sequence, roll forming produces very tight tolerances and an attractive finish. The process allows you to add tooling to create any shape, no matter how complex.
Because the material is coiled and fed through, there are no limits on length. Roll forming is more cost-effective at high volumes. It allows in-line fabrication (lower labor cost) and can form high-strength steels while accommodating springback.
There are only a few distinct drawbacks to the roll forming process:
Roll forming performs best for projects that require medium to high volumes, tight tolerances, and an attractive appearance. You can learn more about it via the button below:
A press brake bends metal (usually sheet metal) to a predetermined angle by pinching it between a punch and a die. Press braking is efficient and cost-effective compared to other metal forming options, but only when working with small volumes and shorter part lengths.
A brake press is easier to set up than other metal parts manufacturing services (depending on the number of dies needed for the complete forming sequence). It usually saves you both time and overall cost.
Brake press tooling is also often less expensive than roll forming or stamping.
Larger orders can (and do) get expensive quickly because brake forming is labor intensive. Brake presses also cannot handle longer parts due to their relatively small sizes and designs.
Press braking runs into a few challenges in its forming process as well:
Press braking might be ideal if your job doesn't require tight tolerances, if you don't necessarily care about initial appearances, and if you have small order volumes.
Stamping involves placing a flat sheet (or coil) of metal into a stamping press, where a tool and die apply pressure to form the metal into a new shape or cut out a piece of the metal.
Stamping has been the go-to process for many years due to its ease and affordability.
Stamping also offers:
Stamping cannot produce long parts as it fights springback and leaves tool marks and scratches on the products.
In addition, metal stamping equipment has difficulties:
The cost of metal stamping is highly dependent on your specific project needs. Jobs with shorter parts, parts of the same size, and no need for initial aesthetics may benefit from stamping.
Extrusion is a metal forming process that forces metal through the die of the desired cross-section. You can think of the extrusion process as a Play-Doh squeezer or a pasta machine. The material is forced through a die while still soft to create the desired shape.
The consistency of the die means an extruded part will have very tight tolerances.
Unlike press braking and stamping, extrusion allows for multiple cross-sections, wall thickness control, and incredibly low tooling costs.
There are four main disadvantages to extrusions:
Extrusion is best for projects with thick walled (0.060” +) aluminum, non-steel, and non-fabricated parts.
We can't stress enough that each metal production method has distinct advantages and disadvantages, and the nature and goals of your project will heavily influence your choice:
When it comes to metal parts manufacturing, our expertise lies in roll forming. The free e-book below is a great initial tool for understanding how to make a more manufacturable and successful roll-formed part:
(Editor's Note: This article was originally published in January 2016 and was recently updated.)