Forging the Future: The Art of the Metal Fabrication Process
- Madden Fabrication
- Jun 26
- 5 min read
The metal fabrication process is at the core of modern manufacturing and construction.
From bridges and buildings to art and intricate machinery, this complex process involves precision cutting, bending, welding, and assembling to transform raw metals into essential parts of everyday life.
In this article, we’ll explore the steps, techniques, and applications of the metal fabrication process, and where to find expert metal fabricators to complete your Portland metal fabrication project.
Table of Contents
What Is Metal Fabrication?
Metal fabrication is the process of transforming raw materials, usually sheets of metal, through a step-by-step process that creates a specific end product, such as metal livestock stanchions, jet engine parts, and irrigation pivots.
The metal fabrication process involves a series of steps, including:
Design
Cutting
Forming
Assembly
Finishing
Installation
Maintenance
Madden Fabrication offers a wide variety of metal fabrication services, including:
Railings
Custom metal awnings
Beams; and
Metal gates
Contact us today to learn more!
7 Steps of the Metal Fabrication Process
#1: Design
First and foremost, the project must be designed. These days, design is generally accomplished through the use of computer-aided design (CAD) software, which enables increased complexity and precision, as well as the ability to create and test models to exact specifications.
If your project includes replicable parts, like panels, brackets, fittings, or housings, a working prototype will likely be created before the project moves into full production. Pre-production testing provides the customer with a sample of the finished product's quality and allows them the opportunity to test the product in real-world applications.
#2: Cutting
There are a variety of ways to precisely cut sheet and plate metal, including:
Laser cutting uses a focused laser beam to cut materials and is the most precise method for cutting sheet metal, especially in designs where intricacy or extreme accuracy are required.
Water jet cutting utilizes a high-pressure stream of water, or a mixture of water and abrasive, to cut through various materials and excels at creating precise, intricate shapes in a wide array of metals, especially when you want to avoid heat-affected zones or distortion.
Mechanical shearing uses a machine with blades to apply a high force that fractures the material and is one the best choices if the sheet metal is thick and requires more physical force for a proper cut.
Since cutting metal provides a very low tolerance for error, selecting the right method is critical.
To choose the best cutting option for a project, the fabrication will consider the:
Type of metal
Intended purpose
Degree of precision required
Thickness and hardness of the metal
#3: Forming
Forming the metal involves bending or otherwise deforming it to create structural parts and components, and may be done through:
Stretching: Elongating metal sheets by applying tensile force with minimal distortion
Casting: Heating the metal to its melting point then pouring the molten metal into a mold and cooling
Roll forming: Feeding metal strips through a successive set of rollers, incrementally forming it into the desired cross-sectional shape
Shearing: Using scissor-like forces to cut and slice metal sheets
Bending: Using directional force to bend metal around an axis
Welding: Utilizing manual or robotic means to join two pieces of metal by heating localized areas until they melt together
Stamping: Using a stamping press, tool and die to apply pressure to imprint, bend, or cut out desired shapes all at once.
Forging: Applying localized compressive force to metal that’s been heated to reach a malleable point
Punching: Applying force with a punch and die to shear holes into metal sheets, similar to a paper hole puncher.
And more
#4: Assembling
Once the metal has been formed into the correct shape, the parts must be assembled to create the final product.
As the pieces are fitted together, they are often held in place by clamps until the fusing process is complete. Parts are then assembled using:
Welding
Bonding
Screwing
Riveting
#5: Finishing
The final step involves the application of protective coatings that include rest-resistant paint colors or glazes. These may be applied by painting or the use of powder coating. Depending on the requirements for the final product, it may also be polished, brushed, or finished with a shine.
Now it's time for any finishing touches. These might include applying:
Decals
Insulators
Safety mechanisms
#6: Installation
Some fabricated pieces, like small parts, brackets, or consumer products, don’t require professional installation.
Other projects require the skill, expertise, and equipment of professional welders, pipe fitters, and engineers. These projects may include fixed metal signage, large structural elements, or automated food processing equipment.
If the finished product requires installation, selecting a one-stop shop makes the metal fabrication process seamless. At Madden Fabrication, our team of metal professionals takes your project from design and planning to fabrication to installation.
Our reliable and experienced staff provides clients with exceptional service for a broad range of work. Whether you need one-of-a-kind custom lighting, detailed railings or industrial piping Madden Fabrication can get the job done right.
Contact us today to find out more.
#7: Maintenance
Maintenance of your metal fabrication project is crucial to ensure your equipment’s:
Longevity
Consistency
Operational efficiency
Safety; and
Cost-effectiveness
Madden Fabrication is a full-service metal fabrication facility, providing maintenance and repair and our team offers a comprehensive suite of maintenance services designed to meet your needs. We’re equipped to handle any challenge, ensuring your facility remains safe and efficient and with our wide range of capabilities, we can tailor our assistance to your specific requirements.
Trust Madden Fabrication to be your partner in maintaining and enhancing your facility.
Types of Metal Fabrication Services
Metal fabrication provides a diverse range of services to cater to the needs of both large and small projects. These options range from:
At Madden Fabrication, our expertise extends to custom projects of all sizes, ensuring we meet your unique needs with precision and flair. Whether it's a functional necessity or a decorative touch, trust us to bring your vision to life.
Madden Fabrication: Commercial, Residential, and Industrial Metal Fabrication in Portland, Oregon
If you’re looking for a professional metal fabricator, the team at Madden Fabrication would be honored to discuss your project with you.
Located in Portland, Oregon, Madden Fabrication is a metal fabrication facility serving the industrial, commercial, and residential construction industries.
We can provide shop-fabricated products and field installation or repairs to meet your specific requirements or detailed specifications.
Our reliable and experienced staff specializes in:
Carbon steel
Stainless steel
Aluminum
Nickel alloys
Exotic metals
We take pride in our precision, innovation, and excellence. Get started on your next project today with Madden Fabrication.
Comments