Sheet metal parts are commonly manufactured from carbon steel, stainless steel, aluminum, galvanized steel and copper alloys. Material selection affects strength, corrosion resistance, weight, formability, weldability, surface finish and service life.

We provide custom sheet metal fabrication, laser cutting, CNC bending, stamping, welding and surface finishing for prototypes and low-volume production.

Common Sheet Metal Materials

MaterialCommon GradesKey PropertiesTypical Applications
Mild SteelA36 / Q235Good strength, weldability and formabilityFrames, brackets, enclosures
Carbon SteelA572 / Q345Higher strength than mild steelStructural parts, machinery
Stainless Steel304 / 304LExcellent corrosion resistance, good formabilityFood, medical, industrial equipment
Stainless Steel316 / 316LExcellent corrosion and chemical resistanceMarine, chemical, medical
Aluminum5052Excellent formability and corrosion resistanceEnclosures, panels, brackets
Aluminum6061-T6High strength, lightweight, machinableStructural components, machinery
Aluminum7075-T6Very high strength-to-weight ratioAerospace, high-performance parts
Galvanized SteelG90 / DX51DCorrosion protection with good formabilityEnclosures, HVAC, construction
CopperC11000Excellent electrical and thermal conductivityBusbars, electrical components
BrassC26000 / C36000Good corrosion resistance and machinabilityDecorative and electrical parts

Material Selection Guide

RequirementRecommended Materials
General sheet metal fabricationA36 / Q235
High structural strengthA572 / Q345
Corrosion resistance304 / 316 Stainless Steel
Marine environment316 / 316L
Excellent formability5052 Aluminum / 304 Stainless
Lightweight construction5052 / 6061 Aluminum
High strength-to-weight ratio6061-T6 / 7075-T6
Outdoor applicationsGalvanized Steel / Stainless Steel
Electrical conductivityC11000 Copper
Good machinabilityC36000 Brass
Cost-effective enclosuresMild Steel / Galvanized Steel

Common Failure Factors

  • Corrosion: rust, pitting and surface degradation
  • Fatigue: cracking caused by repeated loading
  • Buckling: deformation of thin sheet under compression
  • Creep: long-term deformation at elevated temperature
  • Weld failure: cracking, distortion or insufficient joint strength
  • Galvanic corrosion: corrosion between dissimilar metals
  • Surface damage: scratches, coating failure and oxidation
  • Excessive bending: cracking or permanent deformation

Sheet Metal Design Considerations

When designing sheet metal parts, consider:

  • Material thickness
  • Bend radius
  • Bend allowance and K-factor
  • Minimum flange length
  • Hole-to-edge distance
  • Hole-to-bend distance
  • Tolerances
  • Weld and fastener locations
  • Material grain direction
  • Surface finishing requirements

Avoid placing holes or cutouts too close to bend lines, and use an appropriate inside bend radius to reduce cracking and deformation.

Sheet Metal Surface Finishes

Common finishing options include:

Powder Coating · Anodizing · Plating · Brushing · Polishing · Sandblasting · Passivation · Galvanizing · Painting

The appropriate finish depends on the required corrosion resistance, appearance, wear resistance and operating environment.