Category: Metal Fabrication

Metal fabrication is a comprehensive process that involves transforming raw metal materials into finished products. This process includes several techniques such as cutting, bending, and assembling, and is essential across various industries. Understanding the nuances of metal fabrication can help appreciate its significance in modern manufacturing and construction.

As the backbone of manufacturing and construction, metal fabrication’s significance cannot be overstated. This process ensures that structures are safe, durable, and capable of withstanding various stresses and environmental conditions. From towering skyscrapers to delicate medical devices, the precision and expertise involved in metal fabrication are what bring these structures to life.

Understanding Metal Fabrication

Metal Fabrication Definition: Metal fabrication is the act of constructing machines and structures from raw metal materials. This process encompasses various techniques including cutting, bending, and assembling, often facilitated by advanced machinery and skilled labor.

Types of Metal Fabrication Processes

  1. Cutting: This fundamental process involves slicing metal sheets into desired shapes and sizes. Traditional methods like sawing have evolved into modern techniques such as laser cutting, waterjet cutting, and plasma arc cutting, which offer precision and efficiency​.
  2. Drawing: Drawing involves pulling metal through a die to reduce its diameter, often used to create wires. This can be done at room temperature (cold drawing) or at elevated temperatures to ease the process.
  3. Folding: Folding manipulates metal to bend at specific angles, commonly using a brake press. This process is crucial for shaping sheet metal into desired forms​.
  4. Forging: One of the oldest fabrication techniques, forging shapes metal using compressive forces. This can be done at various temperatures, including cold, warm, and hot forging, depending on the metal and desired properties​.
  5. Extrusion: This process forces metal through a die to create objects with a fixed cross-sectional profile, such as pipes and tubes. Extrusion can be performed hot or cold, each method suited to different metals and end uses​.
  6. Casting: Metal casting involves pouring molten metal into a mold to achieve a specific shape. This versatile process is ideal for creating complex geometries and is widely used in manufacturing​.
  7. Welding: Welding joins two metal pieces by melting their edges and fusing them together. Various welding techniques, such as arc welding and gas tungsten arc welding, are employed based on the material and application.
  8. Stamping: Stamping involves placing metal sheets between dies and applying high pressure to shape the metal. This process combines punching, bending, and other operations to form parts with precision​.

Each of these processes plays a crucial role in metal fabrication. Cutting is often the first step, creating manageable pieces from large sheets or bars of metal. Bending follows, shaping these pieces into forms that can be assembled into more complex structures. Welding ensures these parts are securely joined, while machining refines the shapes and dimensions. Finally, assembling brings all the parts together into a cohesive whole.

Metal Fabrication

Structural Metal Fabrication

Structural metal fabrication focuses on creating components for buildings and other large structures. This includes beams, columns, and girders that form the backbone of construction projects. The strength and durability of these fabricated pieces are crucial for the safety and integrity of the structures they support.

In structural metal fabrication, precision and strength are paramount. Beams and columns must be capable of supporting immense loads, often under challenging conditions. The fabrication process involves stringent quality control measures to ensure that every piece meets the necessary standards. This includes rigorous testing for strength, durability, and resistance to environmental factors such as corrosion.

Commercial Metal Fabrication

Commercial metal fabrication involves producing metal parts and products for various commercial applications. This can range from retail fixtures and furniture to components used in the service industry. Precision and quality are paramount in commercial metal fabrication, ensuring that the final products meet the required standards and specifications.

In commercial applications, aesthetics can be as important as functionality. Retail fixtures, for example, must not only be sturdy and functional but also visually appealing. This demands a high level of craftsmanship and attention to detail in the fabrication process. Additionally, commercial metal products often need to meet specific regulatory standards, requiring meticulous documentation and quality control.

Custom Metal Fabrication

Custom metal fabrication is tailored to meet specific needs and requirements. It involves creating unique metal parts and structures that are not available off the shelf. This process is highly flexible, allowing for a wide range of designs and applications. Custom metal fabrication is often used in specialized industries where standard components won’t suffice.

The customization process begins with a detailed design phase, where engineers and designers collaborate to create bespoke solutions. This might involve unique shapes, sizes, or materials to meet specific requirements. Custom fabrication often employs advanced techniques such as CNC machining or 3D printing to achieve the desired results. This approach allows for a high degree of precision and flexibility, catering to unique and complex needs.

How Different Metals Are Fabricated

Different metals require different fabrication techniques. For example, steel is often cut with plasma or laser cutters, while aluminum may be machined or bent using specific tools to avoid cracking. Understanding the properties of each metal is crucial for selecting the appropriate fabrication methods.

Steel, known for its strength and durability, is a staple in construction and manufacturing. Its fabrication often involves high-temperature processes like welding and plasma cutting. Aluminum, on the other hand, is lighter and more malleable, making it suitable for applications where weight is a concern. Fabricating aluminum requires lower temperatures to prevent warping and cracking, and it is often machined to precise specifications.

How Does Custom Metal Fabrication Work?

Custom metal fabrication begins with a detailed design phase, where engineers and designers work together to create precise plans and specifications. These designs are then translated into physical products using various fabrication techniques. The process often involves iterative testing and adjustments to ensure the final product meets all requirements.

The initial design phase is critical, involving detailed discussions and planning to ensure that the final product meets the client’s needs. Advanced software tools are often used to create detailed models and simulations. Once the design is finalized, the fabrication process begins, using techniques like CNC machining, laser cutting, and welding. Throughout the process, quality control measures are implemented to ensure the final product meets all specifications.

Why You Should Outsource Metal Fabrication

Outsourcing metal fabrication can offer several advantages. Specialized fabrication companies have the expertise, equipment, and resources to handle complex projects efficiently. This can lead to cost savings, higher quality products, and faster turnaround times. Additionally, outsourcing allows businesses to focus on their core competencies while leaving the fabrication work to the experts.

By outsourcing metal fabrication, businesses can leverage the expertise and advanced equipment of specialized firms. This can lead to significant cost savings, as there is no need to invest in expensive machinery or training. Moreover, specialized fabricators often have established quality control processes, ensuring that the final products meet all necessary standards. This approach also allows businesses to focus on their core operations, improving overall efficiency and productivity.

Techniques in Metal Fabrication

Metal fabrication employs a variety of techniques to achieve precise results. Some advanced methods include:

  • Laser Cutting: Provides high precision and is ideal for intricate designs.
  • CNC Machining: Uses computer numerical control to automate the fabrication process, ensuring accuracy and efficiency.
  • Water Jet Cutting: Uses high-pressure water mixed with abrasive materials to cut metal without generating heat.

Industries Relying on Metal Fabrication

Numerous industries depend on metal fabrication for their operations. These include:

  • Construction: For beams, columns, and other structural components.
  • Automotive: For frames, body parts, and engine components.
  • Aerospace: For aircraft frames, landing gear, and other critical parts.
  • Manufacturing: For machinery, tools, and equipment.

The Evolution of Metal Fabrication

Metal fabrication has evolved significantly over the years. From ancient blacksmithing techniques to modern CNC machining, the field has continually adapted to new technologies and materials. Today’s fabricators use advanced software and machinery to achieve unprecedented levels of precision and efficiency.

The evolution of metal fabrication is marked by significant technological advancements. Ancient blacksmiths used hammers and anvils to shape metal, relying on skill and experience. The industrial revolution brought about new machinery and techniques, such as steam hammers and rolling mills. In the modern era, digital technology has revolutionized the field. CNC (Computer Numerical Control) machines and CAD (Computer-Aided Design) software allow for precise control and complex designs, transforming metal fabrication into a high-tech industry.

Conclusion

Metal fabrication is a dynamic and indispensable part of modern industry. From the towering skyscrapers that define our cities to the intricate components that power our technology, the impact of metal fabrication is all around us. Understanding this process not only highlights its importance but also underscores the remarkable skills and technologies that make it possible. Whether you’re in construction, manufacturing, or any other industry, metal fabrication is a cornerstone of progress and innovation.

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At Yarbrough Industries, your vision is our passion. We understand you have a lot on your plate. From meetings with project managers to juggling multiple projects, you need a vendor you can trust to understand your exact needs and get the job done right the first time. That’s where we come in. 

We are in the business of finding solutions for all your metal and manufacturing needs. In order to get the job done right for your project, our fabrication services are at your service:

Welding
Our equipment includes a cold saw, vertical bandsaws, a large abrasive saw and a CNC-controlled, auto feed, bundle cutting, and miter capable saw.

Sawing
We can mig, tig, and stick weld stainless, aluminum, and carbon steel of all types. We can also spray weld for shaft or seal surface repair.

Lasser
Using nitrogen gas to remove the secondary processes needed to prep the edge of parts for welding, painting, and forming. We can also etch part names or numbers directly on the part.

Waterjet
The intensifier pump can create up to 90,000 psi of water pressure to push garnet abrasive at speeds of mach3. This power, combined with CNC accuracy, allows us to provide top-quality parts in almost any material.

Metal Bending and Forming
With our CNC press brakes, we can work with pieces up to 200 tons and 12 feet long. Our section roller can roll up to 3 x 3 x ¼ angle and 8 x ¾ flat bar. The universal rollers allow us to roll round, square, and rectangular tubing. Our sheet and plate rolls can handle thin material up to ⅜” x 72”.

If You Can Dream it, We Can Customize it

We specialize in creating tailor-made solutions to fit your specific needs. Whether you’re in need of a small industrial part or a fully custom-built machine, we’ve got you covered. Our team of designers, fabricators, technicians and machinists are at the forefront of technology, and we pride ourselves in our ability to handle projects of any size, no matter how complex.

We understand that in today’s fast-paced world, you need solutions that are both efficient and effective, and that’s exactly what we provide. With us, you can have peace of mind that your project is in good hands. We understand that the complex nature of your work requires flexibility, customization, attention to detail, and thorough communication, which is why we work with you every step to ensure we get every detail right.

Efficiency is the Name of the Game

Imagine having access to the most advanced fabrication technology, where every detail of your parts is brought to life through cutting-edge design software and expertly executed by highly qualified and experienced fabricators. That’s exactly what our fabrication division offers. Utilizing custom metal laser cutting and custom CNC machining, combined with our top-notch quality control and quick turnaround, we bring efficiency and capability to your projects. See for yourself by watching this video and discover the possibilities of what our division can do for you

Trust is key when it comes to choosing a vendor to partner with. That’s why we invite you to tour our facility and have in-depth discussions with our team before making your final decision. Our flawless execution gives our clients the confidence that we’re on their team. We don’t just want to sell you parts or build your project; we want to see you succeed. Trust us to be your partner in success.

How can we make your next project high-quality, efficient and customized to meet your needs?

At Yarbrough Industries, we’re ready to get the job done. Let’s work together!

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Project success is based largely on meeting quick deadlines and staying on budget. When heavy machinery goes down, it can put the entire project in jeopardy. Knowing what resources to utilize during a crisis is essential to get business back on track. 

Working as a team to find a solution to the problem is important. Still, emergencies sometimes require outside support, especially regarding heavy machinery and equipment issues.

Where Can I Find a Qualified Vendor if Emergencies Arise?

While original equipment manufacturers (OEMs) may be your first choice because they can get you the exact part that is needed, they aren’t always the fastest or budget-friendly choice. A reliable, independent vendor can offer quality solutions quickly and usually save time and money. 

A local heavy construction equipment repair company specializing in customer and emergency services will know the importance of quality service. When looking for a reliable vendor in an emergency, be sure to consider a highly-rated vendor that offers warranties on their parts and services in your area

Is There Anyone on Staff That Can Fix my Equipment?

While established team members may be relied upon for emergency repairs, that is not always the best use of their time. Sometimes a third-party solution seems more costly and but when teams lack the technical expertise or simply lack the bandwidth to handle the emergency, having a reliable vendor is priceless. When it comes to heavy machine repairs, every delay means production is slowed or halted. Third party vendors can also be a great solution when key personnel are out of the facility either on vacation or assigned to another project and your team could use increased manpower for the amount of repair work needed. 

How Can I Keep my Project Timeline on Track?

Emergencies happen, but getting back on track is the most critical aspect of project success. Searching for a vendor that does mobile heavy equipment repair service near me? Yarbrough is ready to come to your job site and fix the problem with a part in inventory or fabricate aa custom part for heavy equipment repair. Knowing all the tools in your toolbox when an emergency happens allows for less panic and quick action.

Need help finding the right hydraulic parts?

At Yarbrough Industries, we have a large selection of hydraulic products and offer diagnostic, testing, repair, and replacement services to help get your operations back up and running in no time.

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Supply chain challenges have wreaked havoc across the nation. The increase in out-of-stock items is the new normal. When a part breaks and production is stopped money is on the line. Longer than average wait times and out-of-stock items can be detrimental to business. What if there was another way to get back to work? Finding a reliable and experienced vendor specializing in equipment repair and custom machinery can be a great solution.

Repairs

Working with old equipment can be frustrating. Add in a lack of part inventory, and the stakes are even higher. When a part that’s essential to keep the business running breaks, a solution is needed – and fast. Sometimes a new part isn’t going to get production back on track as quickly as possible. Partnering with a quality machine repair company is a business fundamental… It can mean being able to source a repair quickly and even having the option for an on-site visit for a mobile on-site repair. Time is money and having multiple repair option scan save you both. A repair can be more cost-effective than waiting for an out-of-stock part, but the right repair resource is key.

Custom Machinery

If a part is damaged beyond repair and supply chain constraints simply mean there is no way to get the part in a timely manner, custom machinery can get business back on track. A custom machine shop can create the exact part and eliminate the need to wait on an out-of-stock part to become available. As a local machine shop with expertise in custom machinery we typically have shorter wait times and can get your project quoted quickly. When you choose custom machinery, you get the exact part or machine that will provide the best solution to your problem.

Reliable Vendor

When times are tough and you are fighting out-of-stock shortages that can stop your business, choosing a reliable machine shop is important to get the work done quickly and within budget. When emergencies arise, and the work has to be done out of house to get operations back on track, having a partner you trust with expertise and industry knowledge is essential.

At Yarbrough, we utilize all the tools in our toolbox to keep our customers’ operations on track. Partnering with a local machine shop is a great solution to get quick repairs or custom machinery. Stop worrying about out-of-stock surges and call the expert team at Yarbrough Industries for a free quote today.

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3 Ways to Ensure Your Industrial Service Vendor can Handle Custom Machining Services

3 ways to ensure your industrial service vendor can handle custom machining services yarbrough blog header

Searching “custom metal fabrication near me” is not enough to find a qualified and reliable vendor. It’s time-consuming to find an experienced vendor capable of providing the right services, especially when you need more time designing and building products. When custom machining services are needed, finding a vendor that provides quality metal fabrication and exceeds expectations is essential. Production times, false guarantees or receiving complex parts short of the necessary spec qualifications can drag projects out, leaving engineers juggling tighter project timelines between vendors and clients.

Instead, we’ve put together three ways you can review a custom machining services and quality machine repair service vendor, including top qualities to look for to get the quality custom machining services you need.

1. Review Prior Experience

A great starting place is asking, “Has your team worked on a project like this before?” While it may seem simple, experience is a great teacher. Benefits include vendors who foresee problems, efficiently execute projects and accurately provide complete timelines for projects. A shop that provides various industrial services is more likely to have the techniques and experience to create exactly what is needed for custom machine parts while anticipating any potential problems. An industrial services vendor’s range of products and services provides the first clue of what their team is capable of managing. Ask about experience, not only for the size of the project but also about customization levels. While a smaller shop may specialize in custom machining, they might not have the ability to produce at a high enough volume for another project. Likewise, many high-volume plants lack the ability to create custom parts as the volume of production cannot be interrupted. Either way, it’s best not to assume and hear for yourself about their prior experience as it pertains to current capabilities.

At Yarbrough, we provide industrial services from expert metal fabrication, machine maintenance, engineering, part sales, and in-shop or on-site heavy equipment repair. We’ve also been doing this for over 75 years – giving our teams the experience and expert knowledge to become a one-stop shop for any project. Our high-tech equipment and expert-level knowledge in metal forming and bending has allowed us to work on various projects, from custom machining services to quality machine repair. We offer intricacy in designs and customization of parts — we consult directly with our clients to ensure we successfully execute any and all complex projects.

2. Discuss the Project Specs

The scale of a project for custom machining services greatly affects how vendors approach projects and can also have a large impact on the ability to give attention to details and produce high-quality parts. Some engineers default to high-volume plants for larger projects, but this is not always the best approach. Since these shops deal with many customers, they cannot provide the same quality level of parts and are more liable to produce parts that don’t meet the spec standards set. Yes, it may save a smidge of the budget, but the time spent to have to reevaluate with the spec standards aren’t met is much more costly. Smaller shops are an excellent resource for large projects since they have the same resources to get the work done but have the ability to evaluate complex instructions with more attention to detail.

At Yarbrough, our capabilities extend beyond simple fabrication. Our on-site hydraulics and machining divisions can produce the same volume as larger shops, but can also provide complex, custom machining services and quality machine repair.

3. Consider Project Execution

When dealing with complex custom parts, it’s important to understand the standard operating procedures and processes a vendor has in place to produce what you need accurately and on time. Quick reference guides, project checklists and quality control standards are all great topics that should be brought up for deeper conversation.

At Yarbrough, we pride ourselves on technical precision and efficient workflow. When these two combine, the result is that projects are executed to meet all specifications while delivering on project deadlines.

With a long-standing reputation for excellent customer service, Yarbrough is committed to listening to your needs and executing projects with precision. We build long-standing relationships with our customers as they grow to rely on us time and time again. A Yarbrough partnership means you can redirect your focus where needed most while we focus on the work.

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How to Source Custom Components and Parts With The Right Vendor

how to source custom components blog

Engineers are problem solvers. They find a way to create something that meets a need through ingenuity and technical expertise. However, a new problem arises when trying to figure out how to bring the concept into the physical world. How to find the resources to make the custom components?

1. Figure Out Where

Many engineers have searched for ‘custom metal fabrication near me’ and see numerous results. But parsing through those results can be quite cumbersome. Parts might come from contract plants, machine shops, in-house services, or even brokers looking to connect companies. Local machine shops provide the most options for genuinely custom machined parts. Unlike contract plants that often use assembly lines or in-house shops with less equipment, a machine shop will host a wide range of tools and technology to meet any customization need, like a custom metal laser cutting machine. Their ability to use a range of machines and methods means buyers aren’t limited to just small custom machined parts but can add functionality like hydraulics without using a second location.

2. Ask About Timing

Machine shops know that time is essential and often spread between many projects at once. It’s important to be confident that the part is right the first time and meets the exact specifications required. So while timing can vary by project, some vendors will consult with clients to establish a timeline that won’t make false promises and helps efficiently get work done right. Fast turnaround time is essential, as is high-quality work. An up-front and in-depth discussion between client and supplier helps ensure both are provided.

3. Check The Work

Vetting vendors can be a time-consuming process, and the last thing busy managers need is to do this process repeatedly, trying to find quality work. Touring facilities and consulting with fabricators are significant steps in ensuring trust in the process. Through these discussions, companies can rule out any potential issues and make sure every design step is understood and in good hands. Vendor reputation can also be a valuable indicator of quality.

Custom machined part orders can have much more detail than the drafted design. In addition to size and shape, there are product qualities like material and grade, product finish and construction style and type. Translating a sketch or even a 3D rendering into a completed product can require considerations that are not always immediately apparent. A vendor with knowledgeable technicians will watch out for these factors, and one with a wide range of equipment protects against assembly line inaccuracy.

No matter what parts a company is looking for, the right vendor is critical to ensure that the full design is done well. The right vendor will work with clients to understand their needs and source a project appropriately, whether that is obtaining parts from a manufacturer or creating them through custom fabrication.

Need help finding the right hydraulic parts?

At Yarbrough Industries, we have a large selection of hydraulic products and offer diagnostic, testing, repair, and replacement services to help get your operations back up and running in no time.

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Why Yarbrough Industries is a Regionally Trusted Vendor

why yarbrough industries is a regionally trusted vendor blog

Finding a vendor is complicated. Finding a vendor you trust is even more complex. Many things play into what builds trust: fast and reliable service, reasonable pricing, and good customer service.

1. Exceptional service

Fast and efficient service is what you will receive when you contact Yarbrough Industries. Once you submit your inquiry, you will receive a quote back from Yarbrough Industries within a day.

Most often, we can respond to an RFQ within 1 hour for in-stock items, and within 3 hours for special orders that we need to research.

2. Trustworthy Pricing

When you choose Yarbrough Industries as your vendor, you aren’t only paying for the part but also for reliable service and availability. Our prices are trustworthy and competitive – even if we’re not the lowest, we’re always the best at what we do. 

3. Reliability

Yarbrough Industries is regionally trusted with local feeling. When you walk into a locally owned store, you KNOW they will have what you need? If they don’t, they will follow through on getting it for you. That’s what it’s like at Yarbrough Industries! You get the local feel across the region wherever YOU are! We have the most extensive inventory and top-of-the-line Yarbrough equipment in the 4-State area. 

Yarbrough Industries is a regionally trusted vendor because of our exceptional service and trustworthy pricing, and you are always treated like a local. Do you want service from a local shop with the capabilities and inventory of a large vendor? If so, then Yarbrough Industries is the vendor for you. 

Need help finding the right hydraulic parts?

At Yarbrough Industries, we have a large selection of hydraulic products and offer diagnostic, testing, repair, and replacement services to help get your operations back up and running in no time.

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6 Tips to Reduce Machine Maintenance Costs

6 Tips to Reduce Machine Maintenance Costs

Whether you work for a large manufacturing company or a smaller facility, if you are responsible for overseeing machine and equipment maintenance, you know how important it is to keep costs down and reduce unscheduled downtime.

Luckily there are a few ways you can minimize equipment service and control repair costs. Here is a closer look at six maintenance cost-reduction strategies you can use.

Monitor Expenses

Monitor Machine Maintenance Expenses

Keeping track of how much you’ve spent on labor, parts, and supplies for specific machines over time will help you determine machines and equipment that cost the most money to operate and maintain. If you find there are machines in need of frequent repair, then you have the information available to make an informed decision when it comes to repairing or replacing.

 If you’re at a loss, a skilled engineer or maintenance technician can help troubleshoot the underlying problem and take corrective action.

 

Create Maintenance Schedules

Create Preventative Maintenance Schedules

While not all equipment breakdowns or repairs are predictable, having a routine preventative maintenance schedule can help keep them minimized by keeping machines operating at their best.

Routine maintenance should involve inspecting various equipment components and ensuring machines are up to the manufacturer’s specifications.You can use the owner’s manual to help create preventative maintenance schedules and stay on top of inspections and routine service.

When it comes to creating preventative maintenance schedules, consider basing them on operating hours rather than on a calendar. Usage times will vary by machine, meaning you could be over or under-servicing your equipment based on actual hours. You can determine if you need to decrease or increase service intervals by periodically reviewing the results.

 

Spend Your Budget Wisely

Spend Maintenance Budget Wisely

Between repairing or replacing a piece of equipment? A good rule of thumb is to weigh repair costs against your machine’s residual value (what you’d get if you sold it today). If repairs cost more than the machine is worth, apply your money toward a new machine with better technology that will last longer. 

When it comes time to replace a piece of equipment, keep in mind investing in a lower-priced machine may end up costing you more in the long run. While higher-quality machines may cost more upfront, they typically require less maintenance work overall if maintained.

 

Optimize Equipment and Parts

Optimize Spare Machine Parts

One of the best ways to keep machine maintenance costs down is to develop a strategy to buy and organize spare parts. If you don’t have spare parts such as hydraulic pumps or hoses in stock, then you run the risk of increasing your average repair time.

Aside from keeping an adequate supply of spare parts handy, it helps to ensure there is a degree of similarity between your machines so you can use them interchangeably. Having the same parts fit many machines is cost-efficient and makes it easier to receive technical assistance from either the manufacturer or a professional service technician.

When it comes to purchasing parts, keep in mind ordering parts in bulk will allow you to negotiate better prices.

 

Train Your Machine Operators

Train Maintenance Staff

In addition to training maintenance supervisors and mechanics on equipment, educating your operators can help keep costs down.

Since operators work directly with the equipment, they are in an ideal position to help identify potential problems and perform more common maintenance tasks such as inspection and lubrication. By training non-maintenance staff, you will have fewer periods of unscheduled downtime and avoid expensive and time-consuming repairs.

 

Contact Qualified Service Technicians

Call Qualified Service Technicians

While having a reliable in-house maintenance staff is ideal, the skills to maintain or repair certain pieces of equipment properly will vary. If a machine goes down, trial and error can be an expensive way to learn how to repair your equipment.

If maintenance or repair seems questionable, make sure to contact qualified technicians trained with the right skills and practices needed to minimize unplanned downtime and repair costs. This will save a lot of headaches and unnecessary costs down the road. 

Need assistance with your machine maintenance or equipment repair?

Our expert technicians provide mobile on-site repair to help get your operations back up and running in no time. 

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how is powder coating important in metal fabrication?

Metal fabricators are a pillar that supports the nation’s infrastructure and economy. Countless aspects of our day-to-day life depends on some form of product fabricated from metal, whether its household appliances or critical medical technology. In short, fabricated metal products are invaluable in society, if they’ve been properly finished by a trained professional.

Why is Metal Finishing Important?

Taken on its own, raw metal has some distinct problems; without proper finishing, exposed metals can eventually corrode and tarnish. Depending on the intended use, unfinished metal-fabricated parts can be eroded by salts, weakened by ultraviolet light or rusted by rain. However, the metal fabrication industry realized many years ago that properly finishing components is essential for enhancing durability and the product’s life span.

Beyond that, correctly finishing metal-fabricated products greatly enhances aesthetics, which in turn, makes the products more valuable and pleasing to the end-user. In other words, metal finishing done right is a win for both the metal fabricator and the customer.

Powder Coating’s Impact on Fabrication

Metal fabricators didn’t always have powder coating as an option, though. In the past, fabricators opted for liquid paint; yet, this process took time, required proper conditions and performed poorly unless professionally applied.

In the 1960s, scientists perfected powder-coating, which was a new finishing process that revolutionized the metal product industry. Powder coating provided immediate advantages over previous finishing methods, giving metal fabricators and product manufacturers a leading edge.

Powder coating improves durability, while offering a premium appearance and lowering environmental impact. Over the years, powder coating has allowed metal fabricators to improve production time while increasing functional protective product properties.

How Does Powder Coating Work?

It’s crucial to understand exactly how powder coating works to fully appreciate its unique advantages. While conventional liquid paint has color pigments suspended in liquid, powder coating operates in a completely dry environment— this is an important aspect in finishing custom fabrication and coatings done through powder coating.

Here’s a brief overview of how powder coating works: dry powder receives a positive electric charge and gets sprayed under pressure to the unfinished metal object that’s grounded with a negative charge. This, in turn, creates an electrochemical change allowing molecules from the powder to attach to the metal. There’s a wide variety of powder bases including acrylic, polyester, epoxy, polyurethane or a blend of the aforementioned. The electric polarization inherent to the process allows entirely uniform coating without runs or sags.

After the fabricated metal parts have a uniform powder coating, they’re then placed in a high-temperature environment— the duration will ultimately depend on powder materials, and temperatures can range up to 400 degrees Fahrenheit. Powder-coated products are fully cured when they’re removed from the oven and can be used immediately.

Powder coating allows for complex geometric shapes to be easily coated with uniform coverage. Upon completion, powder-coated pieces have a solid, molecularly-dense, protective outer layer.

Unique Benefits of Powder Coating

Powder coating finish has a multitude of benefits over other available finishing options. Powder coating, performed by a professional, makes finished surfaces resistant to scratching, fading, wearing, and chipping. Beyond that, powder-coated metal products won’t corrode or rust, maintaining a new appearance throughout the product lifecycle. Powder coating also helps to make products nearly maintenance-free under normal usage, as there isn’t a need for repainting.

Powder-coated metal finishes stack up well when compared to other finish techniques. Since powder coating uses less equipment, requires less application time and takes up fewer raw materials, it’s a less expensive process than alternatives like plating and conventional painting. Powder coating is indeed a reliable process, reducing the amount of rejected work. It’s a cleaner, smoother and superior process than other finishing methods. Powder coating is environmentally-friendly, safe and cost-effective finishing. It’s no surprise that powder coating has such a superior advantage in the metal finishing industry.

It’s crucial to do your research when choosing a metal fabrication expert, as not all companies are capable of completing the same quality of work. Yarbrough Industries has years of experience here in Springfield, honing our skills across the board to deliver a quality product and measurable bottom-line value to our customers.

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metal fabrication, metal fabrication shop, metal finishing, metalwork, powder coating

Laser Cutting For Sheet Metal Fabrication

There are many different methods that metal fabricators use to cut metal, but laser cutting is one of the most advanced techniques. A laser cutter’s ability to make precise cuts at speeds unmatched by other flat sheet cutting methods makes it one of the best sheet metal fabrication choices. There are several benefits to this method of cutting, including:

Competitive Pricing

Laser cutting is a highly automated process, making labor costs minimal when compared to hand-operated machinery. Since costs associated with sheet metal fabrication include labor, operation and machine expenses, this is an important factor to consider. The operating costs and machine costs are fairly average compared to other cutting techniques.

Generally, companies will find that outsourcing laser cutting for their sheet metal fabrication is the most effective option for most projects. Laser-cutting machines can be quite expensive, and most companies find that it is easier and less expensive to outsource this aspect of their fabrication process. 

One of the great things about laser cutters is that there are no dull or worn blades to worry about, making die changeovers a thing of the past. This also means that by placing larger orders, you can reduce costs tremendously, as the automated system does the mapping and planning for each additional piece. 

Although laser cutting isn’t the cheapest cutting technology available, it’s more than affordable for most projects. It has some major benefits over other cutting forms, such as water jet cutting or hand cutting processes.

Unrivaled Speed, Efficiency & Automation

A laser cutting machine can move as quickly as 1,000 holes per minute. Of course, the exact speed will vary depending on the tolerances and intricacy of the parts.

CNC controls typically run laser cutting. The formulas entered into the computer mean each part and product is identically fabricated, leading to fewer defects per batch.

Quality Precision

Laser cutting can create tiny cuts at tight tolerances. However, that’s the tradeoff: the more precision you want, the slower the laser will move. Yet, this highly detailed capability is unique to laser cutting. So, laser cutting is the only type of cutting that will get the job done well if you require intricate cuts.

Beyond that, all laser-cut edges and curves are smooth, sharp, and clean, which means there is very little, if any, burring because the laser melts rather than physically cuts the metal.

The only thing to consider is if your project requires very thick sheets of metal – thicker metals affect the cut’s quality, and a laser will leave some dross (melted metal scum) behind on thick metals. Aside from this dross, there is little to no clean-up involved in the majority of laser cutting projects.

Versatility

The combination of cost, speed, automation, and precision makes laser cutting a great choice for any size product or project. This makes many routine tasks/projects easy, including prototypes, industrial orders, delicate designs, and larger cutouts. Lasers are capable of making holes, slots, tabs, and other cut fabrications with no interruption of the cutting process. The incredible precision allows for tight tolerances on intricately detailed designs. If your project doesn’t require tight tolerances, the laser can move quickly and produce parts at incredible speeds. This makes laser cutting a fantastic choice for a wide spectrum of projects.

Yarbrough Industries is proud to offer laser cutting services for your next fabrication product. We can fabricate any order, whether it includes prototypes, components, or final assemblies. We adhere to the belief that high-quality results can only be achieved through the use of high-quality equipment. Laser cutting offers the ability to cut through various materials and thicknesses at high speeds, producing extremely precise and accurate cuts.

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