Using sheet metal prototyping technology, Fathom delivers high-quality parts to its customers. Whether your project is time-sensitive, high-precision, highly complex, or short production run related, Fathom will meet your requirements.
A sheet metal prototype is a physical example that allows designers to test the function and form of a part prior to mass production. Sheet metal can be used to make both functional and non-functional prototypes. More interest from investors is possible with a prototype as it serves as a tangible example of a design’s durability and aesthetics. It is easier to transition from a metal prototype to the final version of a metal product than it is to transition from a plastic prototype to metal part.
Fiber laser cutting uses laser diodes transmitted through optical fibers to create desired cuts. The process makes less noise while decreasing any personal risk to the machine operator. Fiber laser cutting uses a high-power output and high-intensity level, making it a very efficient manufacturing process.
Water jet cutting uses a high-pressure pump which forces water through a nozzle to make precise cuts. The cut is facilitated by the balance of volume and velocity. To create abrasive water cuts, an abrasive substance is mixed with water.
Micro water jet cutting uses the manufacturing capabilities of water jet cutting to produce parts on a micro-level. Water jet cutting’s high-level of accuracy is what allows for the production of tiny and complex parts.
The wire EDM process submerges a metal piece into a de-ionized water (dielectric) where a charged thin metal wire uses electrical sparks to melt the material and create cuts. The spark’s voltage jumps the gap from the wire to the workpiece which causes the material to melt. The metal wire never contacts the workpiece. The dielectric fluid is used to control the sparks, cool and flush away excess material.
During stamping, a blanked or coiled slit to width sheet metal is loaded in a press where the stamping tool is pressed onto the material. The stamping tool or die contains the desired shape of the part. Stamping may involve punching, blanking, bending, drawing, embossing and more.
Prototype etching may use photochemical machining, chemical milling or acid etching to make a part. Material is selectively removed by using baths of temperature-controlled etching chemicals. Chemical etching is ideal for prototyping because of its shorter lead time and inexpensive tooling.
Like prototype etching, production etching uses photochemical machining or chemical milling to create metal parts with high precision and intricacies. Production etching is perfect for transitioning prototypes into production because it is fast, cost-effective and offers great design flexibility.
Laser cutting uses a high-powered laser beam to cut material. A gas, liquid, or solid-state laser cutting technique may be used. CO2 lasers use a gas state laser using a mixture of carbon dioxide to make cuts. Solid state lasers use laser diodes transmitted through optical fibers to create cuts.
Computer numerically controlled punching uses a machine that moves metal in a 2-axis direction and positions the raw material beneath a punching ram. The punching ram punches a hole or form in the sheet metal. CNC punch press machines can have one head and tool rail design or a multi-turret design.
Fathom’s welding team uses a combination of heat and pressure to fuse two or more parts together. Welding services include arc welding, metal inert gas (MIG), tungsten inert gas (TIG), resistance spot welding, laser welding and oxyfuel welding and cutting.
Fathom offers hardware installation services as part of its complete sheet metal fabricating program. We can ensure efficiency and great quality for both low and high-volume production runs.
Sanding and grinding services are both offered by Fathom. Grinding removes weld or adds any desired cosmetic surface. Sanding can remove scratches or burrs from parts after laser cutting or punching.
Liquid painting is a finishing process suitable for projects where powder coating cannot be used. Liquid painting can result in a professional finish, corrosion resistance, custom colors and more.
During powder coating, a sheet metal part is coated in a powder which is then cured. The resulting professional finish may be matte, smooth, textured and more. Fathom offers a variety of different powder coating finishes.
Sheet metal parts can be screen printed in a variety of different finishes and colors. Fathom can also add a design of your choice to your custom part.
Our team can perform assembly and kitting in-house. Services include installing hardware, manual or automated process, and more. Fathom will ensure your finished part is to your exact specifications.
Use Fathom for your sheet metal prototyping needs. Our services include laser cutting, water jet cutting, Microcut™, photochemical machining and wire EDM. Finishing and post-processing services are also available including welding, deburring, bead blasting, and more. Sheet metal prototyping is just one of 28 manufacturing services offered by Fathom.
Standard lead times are below, but 24hr expedite options are available.
| Parts | Delivery time |
|---|---|
| 1-50 flat part pieces | 2 days |
| 50-1,000 flat part pieces | 5-7 days |
| 1-500 formed parts | 6-8 days |
| 1-5 drawn part pieces | 10-15 days |
| 4 slide tooled parts | 4-6 weeks |
Fathom’s global network utilizes over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Fathom has equipment for sheet metal prototype fabrication, including lasers, waterjet machines, finishing tools, autodeburring, 4 slide machines, multi-slide machines, press brakes, 300-ton presses, 22-ton presses, wire EDM machines, seely slide forming tools and 35-ton blanking presses.
In addition to sheet metal prototyping, Fathom also offers hybridized services that leverage prototype fabrication. Fathom’s team of experts can handle your complex project. A recent case study is listed below where Fathom delivered 20,000 parts in 27 days using 55+ tools, including metal prototype fabrication services:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
Fathom’s nationwide coverage includes 3 US-based locations that offer sheet metal prototyping. Fathom’s manufacturing and prototyping services include CNC machining, injection molding, metal 3D printing, chemical etching and more. Leading US companies have received over 200,000 quotes from Fathom. Our team is ready to provide you with a quote today.
Locations include:
COLORADO
7770 Washington Street
Denver, CO 80229
ISO 9001:2015
ITAR
NEW YORK
1920 Slaterville Road
Ithaca, NY 14850
ITAR
401 W. Shore Boulevard
Newark, NY 14513
ISO 9001:2015
AS910:2016
ITAR
Sheet metal cutting is an efficient manufacturing method for prototyping. High levels of precision can be achieved using sheet metal cutting services, up to 0.0005” depending on the manufacturing process. Additional factors that affect tolerance include the complexity of design, geometry, and raw material.
| Material Thickness | Tolerance | Kerf | Part Volume | Set Up Cost | Lead Time ** | Notes | |
|---|---|---|---|---|---|---|---|
| OMAX WATERJET | Up to 6″ | 0.005″- 0.015″ | .020″/.040″ | 1 to 5,000 | Low | 6-8 days | Metal, glass, plastic, stone, rubber, Kevlar, carbon fiber, ceramics, etc. Taper up to 59° |
| MICROCUT™ | .0005″ – 0.5″ | 0.0005″ - 0.005″ | 0.009″, 0.011″, 0.0196″ | 1 to 5,000 | Low | 6-8 days | Metal, glass, plastic, stone, rubber, Kevlar, laminates, carbon fiber, ceramics, etc. |
| FIBER LASER | AL: 0.250″ SS: 0.375″ CRS: 0.500″ COP: 0.250″ Brass: 0.125″ | 0.002″ – 0.005″ | .008″ | 1 to High-Volume | Low | 6-8 days | Metals - Fast |
| WIRE EDM | 0.001″ – 6″ | 0.0005″ | 0.005″ | 1-200 Is Best | Low | 6-8 days | Conductive Metals, Carbon |
| * CHEM ETCH | 0.005″ – 0.060″ | Is +/- 10% of material thickness, .002″ min. | Equal to metal thickness | 1 - Infinity | $350 Min. | 6-8 days | Metal Only. No Burrs. Beveled Edges. Half Etch and Holes. |
*Inner radius should be 75% of material thickness. Outer Radius should be material thickness plus Inside bend radius.
**Dependent on geometry, volume and material: 24hr Expedite options available
| Alloy | Temper | Ductility | Strength | Corrosion Resistance | Heat Treatable | Comments |
|---|---|---|---|---|---|---|
| 6061 | T6 | Low | Mid | Good | No | Minimum bend radii of 3x raw material thickness. |
| 6061 | T0 | High | Low | Good | Yes | Higher-cost heat treating due to warping and need for secondary straightening. |
| 5052 | H32 | High | Mid | Good | No | Most commonly used aluminum alloy and temper. |
| 5052 | H34 | Mid | High | Good | No | Small radii bends in line with grain may fracture. |
| 3003 | H14 | High | Low | Good | No | Good for deep drawn parts. |
| Alloy | Temper | Ductility | Strength | Corrosion Resistance | Heat Treatable | Comments |
|---|---|---|---|---|---|---|
| 301 302 304 |
*Range | **High | High | Excellent | No | Small radii bends in line with grain may fracture in full hard temper. Full hard temper is cost effective for springs as there is no need for heat treating or plating. |
| 316 316L |
Annealed | High | High | Excellent | No | Used heavily in the medical industry. |
| 410 | Annealed | High | Mid | Mid | Yes | Excellent for springs. Stays stable in heat treating and has a bright finish. |
| 17-4 PH | Annealed | Low | Excellent | Mid | Yes | Small radii bends in line with grain may fracture. |
| 17-7 PH Cond. A |
Annealed | Mid | High | Mid | Yes | Excellent for springs intended for repeated cycles. Remains stable during heat treating. |
| 17-7 PH Cond. C |
Mill Hardened | Low | High | Mid | Yes | Small radii bends in line with grain may fracture. Highest hardness and strength achievable in alloy 17-7 PH. |
*Annealed, 1/2, 1/4, 3/4, and full hard possible
**Ductility decreases in harder tempers and mill hardened materials
| Alloy | Temper | Ductility | Strength | Corrosion Resistance | Heat Treatable | Comments |
|---|---|---|---|---|---|---|
| 1008 1010 |
Soft, 1/2, 1/4 Full Hard | High | Mid | *Poor | **Yes | When rolled at or near room temperature, excellent ductility and strength is produced and is more uniform than hot rolled steel. |
| 1008 1010 |
Annealed | High | Mid | *Poor | **Yes | Rolled at a temperature greater than the recrystallization point, which produces surface scale. Good ductility, but weaker and less uniform than cold rolled steel. |
| HSLA | Annealed | Mid | High | *Poor | **Yes | Requires 25-30% more power to form than cold rolled steel or hot rolled steel. |
| 1050 1074 1075 1095 |
Annealed | Excellent | ***High | *Poor | Yes | 1095 has the highest carbon content of the materials listed. Higher carbon content yields higher strength with less ductility after heat treating. |
| 1095 | Blue Tempered | Low | High | Mid | No | Good for flat springs or leaf springs with large radii. |
*Poor without plating or surface treatment
** Limited to carburizing
*** High strength after heat treatment
| Alloy | Temper | Ductility | Strength | Corrosion Resistance | Heat Treatable | Comments |
|---|---|---|---|---|---|---|
| C10 Cooper | Wide Range | High | Mid | Good | No | Highly conductive. High cost. |
| C172 Beryllium Copper | Wide Range | Excellent | Excellent | Fair | Yes | Excellent for electrical spring contacts. Highly conductive, excellent electroplating adhesion coefficient and remains very stable during heat treating. Moderate cost. |
| C260 Brass | Wide Range | *Ranges | High | Good | No | Small radii bends in line with grain may fracture in full hard and spring tempers. |
| C510 Phosphor Bronze | Wide Range | *Ranges | High | Fair | No | Small radii bends in line with grain may fracture in full hard and spring tempers. |
*Ranges according to temper
Medical, defense, aerospace, electronics, automotive and industrial companies have all used Fathom for their sheet metal prototyping services. No matter what industry, our team can meet the technological and manufacturing challenges your project demands.
A: Yes, Fathom offers metal prototype fabrication.
A: Metal prototype manufacturing is creating a sample or “rough draft” part that can be used to test the form and function before mass production.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Fathom is capable of a same day turnaround for sheet metal parts.
A: Sheet metal prototyping is the use of sheet metal manufacturing methods to produce prototypes. Manufacturing methods may include water jet cutting, chemical etching, wire EDM and more.
A: Sheet metal modeling is the digital process of designing a sheet metal part.
A: Three methods of shaping sheet metal include bending, cutting, and shrinking. Bending sheet metal is accomplished using a metal brake, cutting may be done manually using hand shears or snips and shrinking uses heat which is applied to an overstretched area.
When designing for sheet metal manufacturing in CAD, the thickness of the material, bend radius, and k-factor must all be considered.
Ready to get a quote on your sheet metal prototype? Do you need to calculate costs for an upcoming project? Use Fathom’s SmartQuote application for a fast quote.
