Guide to Sheet Metal Fabrication

For home and business owners in Brooklyn, NY, understanding sheet metal fabrication is key to making informed decisions for your construction and renovation projects. This guide dives deep into the types, finishes, and materials of sheet metal fabrication, ensuring your next project meets both your aesthetic and functional needs.

Types of Sheet Metal Fabrication Processes

metal sheet

Sheet metal fabrication is a comprehensive field that encompasses a variety of techniques and processes, each designed to manipulate metal sheets into desired shapes, sizes, and forms. These processes are crucial for a wide range of applications, from industrial machinery to decorative items. Here’s a closer look at the most common types of sheet metal fabrication processes:


Cutting is often the first step in the sheet metal fabrication process, where metal sheets are divided into smaller, more manageable pieces or specific shapes required for a project. The methods used for sheet metal cutting vary, each with its own advantages:


A straightforward and efficient method where a blade slices the metal along a straight line. Ideal for cutting large sheets into smaller rectangles or squares.

Laser Cutting: 

Utilizes a high-powered laser beam to make precise cuts. It’s highly accurate and can create complex shapes with smooth edges. Laser cutting is versatile, working well with various metals and thicknesses.

Waterjet Cutting: 

Employs a high-pressure stream of water, sometimes mixed with an abrasive material, to cut through metal. This method generates no heat, preserving the metal’s intrinsic properties and avoiding warping or distortion.


Bending differs from cutting sheet metal, as it modifies the shape of sheet metal without removing any material, creating angles and curves. This process is essential for forming sheet metal parts with specific geometries:

Press Brake Bending: 

Involves placing the sheet metal on a die and lowering a punch onto the metal to bend it. The process is highly controlled, allowing for precise bends at specific angles.


Some machines can fold sheet metal along a line by clamping the sheet and lifting a side to bend it. This method is suitable for creating panels and boxes.


Though primarily known for creating shapes or designs, sheet metal stamping can also involve bending parts of the sheet metal to a specific angle.


Welding is a fundamental process for joining two pieces of metal together, making it a cornerstone of metal fabrication. Various welding techniques can be used, depending on the project requirements:

TIG Welding: 

Tungsten Inert Gas (TIG) welding offers a high degree of control, producing clean, precise welds. It’s ideal for thin materials and intricate work.

MIG Welding: 

Metal Inert Gas (MIG) welding is faster than TIG welding and is suitable for a wide range of applications, including higher levels of material thickness.

Spot Welding: 

This method applies pressure and heat from an electric current to the weld area, joining metal sheets without filler materials. Spot welding is commonly used in automotive manufacturing.


Punching creates holes or cut-outs in sheet metal, a process essential for various functional and aesthetic applications:

The technique involves driving a punch through the metal and into a die underneath. The size and shape of the punch and die determine the hole’s dimensions.

Punching is not limited to round holes; it can create slots, squares, or custom shapes, making it versatile for decorative designs or functional features like screw holes and ventilation grates.


Stamping shares similarities with punching but focuses more on creating raised patterns, designs, or shapes in the metal sheet:

Forming Stamping: 

Involves pressing a die into the sheet metal to create a three-dimensional shape or design without cutting through the material.

Progressive Stamping: 

A series of stamping stations each perform a different action on a strip of metal as it passes through a stamping press. This method is efficient for producing large quantities of complex parts.

Each of these processes plays a vital role in transforming raw sheet metal into finished products. The choice of technique depends on the project’s specific requirements, including the type of metal, the desired finish, and the complexity of the design. Understanding these processes allows designers and fabricators to select the most appropriate methods for their projects, ensuring high-quality results that meet or exceed expectations.

Finishes for Sheet Metal

The finish of sheet metal not only affects its appearance but also its resistance to corrosion, its surface friction, and its overall durability. Popular finishes include:

Powder Coating: 

A dry powder applied electrostatically and then cured under heat, providing a hard finish that is tougher than conventional paint.


Used primarily for aluminum, this electrochemical process thickens the metal’s natural oxide layer, enhancing its corrosion resistance.


This involves coating the metal with another metal to provide corrosion resistance, enhance appearance, or increase strength.


Polishing gives the metal a smooth, reflective finish, often used for aesthetic purposes.

Custom Sheet Metal Fabrication

Materials Used in Sheet Metal Fabrication

Different materials are used in sheet metal fabrication, each offering unique properties:


Lightweight and corrosion-resistant, aluminum is ideal for applications requiring high strength-to-weight ratios.

Stainless Steel: 

Known for its strength and corrosion resistance, stainless steel is widely used in both industrial and decorative applications.


Highly conductive and corrosion-resistant, copper is often used in electrical components and roofing.


An alloy of copper and zinc, brass is used for its acoustic properties and resistance to corrosion, often found in decorative items.

Galvanized Steel: 

Steel coated with a layer of zinc to prevent rusting, used in outdoor applications where durability is essential.

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Choosing the Right Sheet Metal Materials for Your Project

Selecting the right material for your sheet metal fabrication project depends on several factors:


Consider the environmental conditions the sheet metal parts will be exposed to, such as moisture or chemicals.


For projects where weight is a concern, lighter metals like aluminum may be preferable.


The appearance of the sheet metal components can be crucial for decorative projects. Metals like brass and polished stainless steel offer distinct visual appeal.


Budget constraints can also influence material choice, with some metals being more cost-effective than others.

Custom Sheet Metal Fabrication in Brooklyn, NY

For those in Brooklyn, NY, custom sheet metal fabrication offers the opportunity to tailor projects to specific needs, whether for construction, renovation, or decorative purposes. Working with a skilled fabricator like ours at Iceberg Mechanical Corp allows you to select the ideal type, finish, and material for your project, ensuring a perfect match for your requirements.

Sheet metal fabrication is a versatile and essential process for many construction and renovation projects, offering a wide range of types, finishes, and materials to meet any need. By understanding the options available, you can make informed decisions that enhance the durability, functionality, and appearance of your projects.

Transform Your Ideas into Reality with Expert Fabrication 🛠️✨

Elevate your next project with the precision and beauty of custom sheet metal fabrication. Whether you’re enhancing your home or elevating your business space in Brooklyn, NY, our team at Iceberg Mechanical Corp is here to bring your vision to life. With a commitment to quality and craftsmanship, we offer tailored solutions that blend seamlessly with your design aspirations. We also offer heating and cooling installation, repair, and maintenance. Reach out today, and let’s create something exceptional together.