Sheet Metal Engineering

Our sheet metal design consultants will help you navigate the complexities of metal fabrication engineering and the dynamic realm of sheet metal product development.

Schedule a Consultation

Fundamentals of Sheet
Metal Engineering

Basics of Sheet Metal Fabrication

Sheet metal engineering transforms raw metal sheets into functional products through engineers’ work on material analysis, thickness dynamics, cutting (laser, water jet), bending, folding, and joining methods like welding and riveting.

Sheet Metal Product Development

Explore sheet metal product development stages, focusing on detail, material properties, design principles, and manufacturing processes for creating high-quality sheet metal products.

  1. Conceptualization and collaboration
  2. Prototyping
  3. Material selection
  4. Tooling and die design
  5. Cutting and forming
  6. Assembly
  7. Quality control
  8. Testing and validation

Sheet Metal Engineering Challenges

  • Material springback: Sheets tend to revert after bending. 
  • Tooling wear affects the precision of bends and forming operations. 
  • Geometric complexities that are hard to achieve without compromising structural integrity.
  • Tolerance management since high tolerances are essential to avoiding compromised product functionality. 
  • Welding distortions affect the geometry and fit of the final product. 
  • Cost efficiency without compromising quality.
  • Environmental sustainability due to energy consumption and material waste.

Sheet Metal Engineering with FC Engineering Services

Our Services and Solutions to Challenges

  1. Sheet metal design and prototyping
  2. Custom sheet metal fabrication
  3. Material selection assistance
  4. Reverse engineering services
  5. Custom packing solutions
  6. Sheet metal consulting
  7. CNC punching design

Request a

Our sheet metal design consultants are highly experienced and will help you meet your metal fabrication engineering project needs.

Schedule a Consultation

Applications of Sheet Metal Engineering

  • Automotive: For lightweight, durable components, enhancing fuel efficiency.
  • Aerospace: Sheet metal’s lightweight and durability are ideal for precise components.
  • Construction: The corrosion resistance and versatility make it a top choice in construction.
  • Electronics: It ensures structural integrity, electromagnetic shielding, and efficient heat dissipation in electronic devices.
  • Medical Equipment: The corrosion resistance is crucial in healthcare equipment fabrication.
  • Energy: Used in lightweight yet robust components, facilitating transport and installation.

Sheet Metal Engineering Best Practices

Our quick recommendations

  • Use techniques that guarantee precise design, material selection, prototyping, precision machining, and efficient manufacturing processes. 
  • Ensure accurate bending, welding, surface finishing, and meticulous documentation for high-quality components.
  • Use an experienced sheet metal design consultant to ensure success.

Featured Projects

Our electrical engineering services expertise derives from working on several projects, such as fixing the Polycom soundstation’s audio issues, the second-generation design of the One Touch Systems digital audio board, and many more.

Machined aluminum drive plate designed in SolidWorks

This drive plate was designed to specific tolerances as a critical component in a system demanding optimum performance levels.

One Touch Systems digital audio board

Design incorporating digital audio and an RF converter that converts base-band video to NTSC channels 3 and 4. Functions also on this board are Analog telephone interface (FCC Part 68); RS485 serial communications; Display and front panel I/O; ISA bus interface.

Polycom SoundStation

High-end audio-conferencing equipment with audio quality achieved by grounding and power distribution techniques, as well as acoustic separation of the microphones and speaker – designed using a full-room anechoic chamber.

Acutus AcQMap System

Designed to provide a clear image of a heart’s electrical activity in real time, displayed as an electrical charge density map on three-dimensional surface anatomy reconstructed from ultrasound imaging.Designed to provide a clear image of a heart’s electrical activity in real time, displayed as an electrical charge density map on three-dimensional surface anatomy reconstructed from ultrasound imaging.

Phoenix ICON Ophthalmic Camera

Designed with low-power LED and CMOS sensor to provide highly-detailed ophthalmic imaging with low-light – improving patient comfort and care.