From construction beams to custom enclosures, fabricated sheet metal is everywhere. But the metal you see or use didn’t start that way. Sheet metal manufacturing turns ordinary flat pieces of metal into the specific components and products that power modern equipment and machinery.
At Champ Metal Fabrication, we understand fabrication as a coordinated system of design, technology, and skilled craftsmanship. Our sheet metal fabrication processes follow a proven path that begins with design and prototyping, proceeds through material selection, cutting, and forming, and concludes with welding, coating, and inspection. With every step, we prioritize accuracy, repeatability, and efficiency so customers know exactly what to expect from design to delivery.
Keep reading to learn more about our capabilities, equipment, and workflow.
Design & Prototyping
A successful project begins with design. Our engineers use CAD software to translate concepts into detailed drawings that specify dimensions, tolerances, materials, and finishes. These digital files are the foundation for manufacturability reviews, in which we anticipate forming and fabrication challenges before production begins. Prototyping often follows, which gives customers a working sample with which to validate design decisions (or make revisions) and ensures the final product meets expectations. This upfront investment reduces costly rework and scrap later and helps speed up production.
Material Selection & Cutting
Not all sheet metal has the same mechanical properties, and this directly impacts its formability and final performance. At Champ, we work with carbon steel, aluminum, stainless steel, and specialty alloys. We carefully match each project with the right metal for its environment and application.
After selecting the right materials for the job, cutting begins with one of several operations including shearing, laser, and plasma cutting, depending on the complexity of the cuts. Laser cutting is particularly effective for achieving burr-free edges with tight tolerances, often within 0.005 inches. The result is a clean, precise blank that’s ready for forming.
Forming & Shaping
After cutting, sheets are transformed into three-dimensional parts. Press brakes with punch-and-die sets are used to bend metal into exact angles, while roll forming handles long profiles by gradually shaping them through multiple passes. This stage requires advanced equipment and skilled operators who understand the material’s behavior under stress.
Whether creating a series of uniform bends or fabricating a curved profile, forming turns flat sheet metal into components that are structurally sound and ready for assembly.
Tools, Machines, and Staff Involved
Behind every finished part is a combination of high-tech equipment and highly trained people. Champ Metal Fabrication invests in both.
Our production floor includes CNC lasers, turret punches, routers, and hydraulic press brakes that are programmed with G-codes that guide the machines and ensure a highly repeatable process. Additional equipment, such as mills, lathes, and drills, performs precision machining where required.
Welding stations support MIG, TIG, spot, laser, orbital, and arc welding, allowing us to join components with strength and consistency. Finishing tools handle grinding, coating, and surface treatments to complete the product.
But machines are only part of the process. Engineers validate designs and program tool paths. Machine operators oversee cutting and forming. Welders ensure assemblies meet structural standards. Quality assurance technicians inspect every dimension, weld, and finish before parts leave the floor. It’s this collaboration of people and technology that ensures success.
Timeline and Project Flow
A typical Champ project begins with sourcing material, which usually takes three to seven days, depending on availability. Cutting, forming, and welding are often completed within one to two weeks for standard jobs. Finishing, such as powder coating or painting, may add a few additional days.
Custom projects, specialty finishes, or complex assemblies can extend timelines to six to eight weeks. Prototyping, sourcing rare materials, or coordinating with outside vendors may also add to the timeline. That’s why early RFQ submissions and clear communication are so important.
One advantage Champ Metal Fabrication offers is that everything happens under one roof: design, fabrication, welding, finishing, and inspection. This eliminates the delays that often occur when multiple vendors are involved. By streamlining handoffs, we keep projects on schedule and reduce the risk of errors.
Understand What to Expect With Champ
Sheet metal fabrication projects work best when they are treated as a partnership between fabricators and their customers. At Champ Metal Fabrication, our approach to sheet metal fabrication ensures precision at every stage, from CAD models to final delivery. By combining advanced technology, skilled staff, and efficient project flow, we deliver parts that meet specifications, deadlines, and quality standards.
Whether you’re seeking help with material selection, need a reliable partner for high-volume runs, or want support for a custom prototype, our team is ready to guide you through the process. Contact us today to get connected with a member of our team for more information.