Sheet Metal Prototype Fabrication Supplier
KDM provides sheet metal prototype fabrication service using state-of-the-art machinery. This ensures a fast turnaround of projects with excellent accuracy.
- Made of zinc, aluminum, stainless steel, copper, and steel
- Offers anodizing, bead blasting, and other finish options
- Custom thickness and size options
- Produces durable prototyping parts
KDM Sheet Metal Prototype Fabrication
Sheet metal prototype fabrication is a process of turning metal sheets to produce parts for prototyping applications. The process involves stretching, bending, and material removal. It can be also done by a laser-operated machine cutter to create weldable and flexible prototypes.
Durable prototypes serve as physical samples of a design idea. It allows you to test the design performance and identify defects before production begins.
KDM sheet metal prototype fabrication services give cost-effective solutions for your projects. Our services include punching, bending, and cutting sheet metals. In this fabrication, we can produce end-use prototypes with wide options of finishes and materials that meet your requirements.
Sheet Metal Prototype Series
Customize prototype enclosure is designed specifically for the application. They are also lightweight, safe, environmental-friendly, fire-resistant, and cost-effective.
The folding and pressing parts are sheet metal prototypes processed through pressing and folding. It is a more robust prototype that can identify probable mistakes.
Sheet Metal Prototype By Process (5)
Folding Parts Prototype
Folding parts prototype are parts processed by folding sheet metal. During folding, you can have perfectly shaped parts. Mostly, it is used in the architectural industry.
Press Parts Prototype
All press parts prototypes have higher accuracy and great dimensional precision. Metal pressing is a process that achieves innovative and complex part designs.
Welded Sheet Metal Parts
The welded sheet metal brackets are prototype processed through welding. These Parts are durable and strong, they included are regulators, nozzles, torches, and more.
Sheet Metal Prototype Benefits
We provide a less expensive sheet metal prototype fabrication service. All prototypes we offer can benefit your business.
Our prototype models have flexibility and durability. It is used to test the design performance and spot defects before manufacture.
We create sheet metal prototypes with complex and high-strength designs. Each component enables you to test product features.
All models have consistent, improved quality, and full-strength designs. It is used to identify errors quickly.
How Does Sheet Metal Prototype Fabrication Works?
Part of the designing process is the sheet metal prototypes. Designers need them for their clients to view and early detect defects. Unlike drawing, it works easier to understand and explain.
They are physical models that become crucial in making design adjustments. Using prototypes can help manufacturers save both money and time in the manufacturing processes.
Allow KDM to help with your prototypes needs! We manufacture prototypes with different constancy levels to meet your design concepts. With our sheet metal prototype fabrication, you can authenticate and process your designs so your brand can deliver accurate products. KDM can fabricate for you. We guaranteed flawless products and less expensive services.
Methods Used in the Fabrication
KDM offers multiple sheet metal processing options to produce prototype parts. It is advantageous to choose the method during the prototype step as a validation step. Some of the key processes include:
- Making the pre-made shape that will be utilized to produce the final part. This can be achieved with the laser cutting process, blanking, punching, or water jet cutting.
- Add up features like notches, slots, holes, and imprints.
- Curving or forming pre-establish into shape.
- Included fixings such as screw studs or clinch nuts.
- Welding the final part if needed.
Advantages of Sheet Metal Prototype Fabrication
Sheet metal prototypes provide numerous advantages for your company or brand. Every prototype model sometimes shows errors like misalignments, overlaps, gaps, and other issues. To avoid such errors, the designs need to be analyzed and reviewed. Below, we discuss further advantages. It includes:
- Detects improvements.
- Early detection of design issues.
- Evaluation of manufacturing costs, production time, and material needs.
- Inspection to guarantee durability and fit.
- Choose machinery needed for manufacturing.
- Collect great feedback from your end-users and customers.
Choose KDM Sheet Metal Prototype Fabrication
Do you need help with your prototyping in business? KDM can be your reliable partner. We produce and develop sheet metal prototypes to elevate your successful product launching.
KDM has wide capabilities for sheet metal prototypes fabrication, assemblies, and weldments. During the development, we use automated and manual machines to create prototypes according to your desired assembly, cuts, bent, and forms.
Our team is consists of highly-experienced project engineers that will work with you. We also have a friendly customer service staff that will help you understand your sheet metal production needs. They will guide you through available processes and materials to get you your exact prototypes.
We got your back if you need sheet metal prototype fabrication. Please contact us today!
Buff Polishing –It provides a smooth finish. This technique is often used for prototypes that need luster.
Metal Plating –This technique is processed with machines that utilize chemical baths. Its advantages include corrosion resistance, durability, etc.
Sand Blasting –Popular technique if prototypes need matte texture.
Powder Coating –Used to apply decorative texture for prototypes. It makes the prototype to be more durable while giving glossy and textured surface appeal.
OEM & ODM Prototypes for Multiple Industry
The roofing prototypes include panels, closures, and more. These are made of multiple sheet metals such as aluminum, copper, steel, stainless steel, and more. Used in the roofing industry due to replaceability, sustainability, and cost-effectiveness.
“KDM offers sheet metal prototypes and amazing services. It amazes me how they support my request and assist me the whole process, from initial design, manufacturing, until the delivery.”
“I highly recommend KDM especially if your projects or business requires sheet metal prototypes. Their team is powerful in providing the most accurate products and services.
“I will definitely choose KDM to help me with my next sheet metal prototype needs. I got accurate prototypes orders in a safe and timely manner.”
Sheet Metal Prototype Fabrication: The Ultimate Guide
Before starting any sheet metal prototype fabrication process, read this guide.
It covers all the vital aspects about fabricating sheet metals.
Take a look:
This is a production process that focuses on turning metal stock into usable parts. Sheet metals used are not flat as perceived.
They have a thickness of 0.006-0.25 inches. Metals that are thinner than 0.006 are called ‘foils or leaf metals’ while those thicker than 0.25 are ‘metal plates.’
Generally, prototypes verify the design intent for production.
So, by fabricating sheet metal prototypes, you can easily tell if the process is worth it or not.
Sheet metal fabrication
i. Physical product– you get the opportunity to hold a tangible miniature of the product in the initial stages of the production process.
It gives you the opportunity to review the design, the methodology and also able to get feedback from the customer or the production team
ii. A functional prototype allows fit, form, and functional testing
- Fit– this is the first test of sheet metal formed parts at the prototype stage that clearly shows errors such as the gap, misalignment, overlaps, etc.
Once the errors have been identified they are reviewed to establish whether they occurred during the design process or the production process.
If the prototype has errors, another prototype has to be made to correct the errors made before making the final product.
- Form– this is all about the aesthetic value of the prototype. How it looks in terms of the size, weight, color, and finished look. We review whether or not change is required.
- Function– some prototypes are not functional its okay if they serve the purpose. However, functionality is the main reason we make prototypes to ensure they perform as intended before going ahead and making the end product.
The prototype is tested against all the design calculations and parameters such as strength, stress, impact, performance, reliability, and any other thing that is design-related.
iii. They help you get rid of guesswork in the manufacturing industry.
You are able to see the product and test the errors before creating the end product.
They may be costly but imagine going ahead and making the actual product and then you realize it has a whole batch of errors and you have to re-do the entire process.
You repeat the same process then God forbid you make a mistake again. You will run mad! Save yourself from all this stress.
Make prototypes first they may cost you but not as much as re-doing an already done project. Fix a whole lest you will build an entire wall.
Sheet metal prototype fabrication
Consider the following factors to reduce the price of sheet metal prototype fabrication:
i. Raw materials– The materials used to manufacture your parts affect the overall price. Materials like magnesium are less expensive than stainless steel.
The thickness of the material also affects the price of the prototype.
That said pick materials that have properties that will fulfill your project’s demand. Do not compromise on the quality because of the price.
Remember cheap is always expensive. Ensure the raw materials are quality and functional.
ii. The complexity of the design- while we encourage creativity in the production industry.
You will pay more for a complex design as opposed to a simple one.
A design that is simpler and requires fewer cuts, mills, bends, etc. is going to cost the least.
A part that requires many cuts or several bends is going to cost more time on each machine and we all know time is money.
The design may cost more in both the design and prototyping phases.
Accuracy goes hand in hand with the design.
If accuracy is a not major factor the machine can be set to handle the process quicker.
But if it is a factor and even the smallest details are necessary, you will pay for the machine to work at a slower pace to capture all the nitty-gritty.
iii. Finishing – a prototype that needs no finishing will be goods to go after getting out of the manufacturing machine.
But most parts of the prototype need smoothening, or sanding of edges.
After the assembly process, they need extra polishing and painting according to your needs.
iv. Quantity– the more prototype samples required the higher the cost.
However, the cost per item reduces once you order more especially if the design is the same hence we don’t have to set up the machine again.
This will reduce the cost of labor hence reducing the price.
Of course, other factors such as type of machine and cost of labor will also play an important role here.
We begin the process with a flat piece of metal then we convert it into a product. The process involves 3 different steps:
Cutting sheet metal
i. Cutting process– here the sheet metal is operated to create cuts using special pieces of machinery. We use plasma cutters, CNC laser cutters, and water jet cutters.
ii. Deformation process– in this process the shape of the sheet metal is converted by either stretching or drawing. We use press brakes and metal stamping process.
Press brakes makes it possible to bend sheet metals into the preferred shape, design, or angle you want. Metal stamping on the other hand allows you to perform specific tasks like embossing, hemming, and drawing.
iii. Assembly– this is the third part of the process. Here different sheet metals are joined together by the use of welding or fasteners.
Welding is the most popular method as there are different methods including plasma arc welding, electron beam and laser welding, etc
Example; if you want to fabricate and assemble two 45 degrees angle brackets, you need to create important features like holes first on the flat sheet metal parts using a laser cutter, water jet cutter, or plasma cutter.
Then place these sheets of metal between the punch and die of the press brake and bend until you the 45 degrees. In the end, fasten or weld the parts together to form the desired shape of the metal fabrication prototype needed.
Almost all engineering materials are used in the form of sheets. Some of the metals include; aluminum, stainless steel, copper, and magnesium
Choose metal according to the end use of the product bearing in mind different metals have different strengths and abilities. They include:
i. Aluminum– pros; Its lightweight, corrosion-resistant, electrical and thermal conductivity, it’s recyclable, it’s odorless and impermeable, reflective and ductile, versatile and flexible.
cons- has a lengthy and expensive welding process. it’s not as strong as other metals i.e. steel
ii. Stainless steel-Pros; It has superior durability, corrosion resistance, is recyclable, readily available, easy to clean and maintain, economical, and has excellent mechanical properties.
Cons; Tends to be more expensive than alternative metals, it’s difficult to weld and fabricate, and its rings can bend after some time.
iii. Copper– is a good electrical conductor for wiring; it is not reactive so can be made into water pipes
Cons- it corrodes easily and is costly
iv. Magnesium metal– pros; they offer high strength and durability, and they are lightweight.
Cons- it’s highly flammable and combustible. There is a high risk of fire and explosion during and after the fabrication process.
For all your prototype sheet metal fabrication needs, contact us now.