A guide to components for metal fabrication
Metal fabrication is like a metalworking recipe book, with various processes acting as the instructions to transform raw metal into desired shapes and objects. Each process requires specific tools and components to ensure precision, efficiency, and durability.
We can enhance these processes with our comprehensive range of components for metal fabrication, providing solutions for protection, sealing, and efficient assembly to ensure high-quality and durable products. In this guide, we’ll break down the common processes and look at the components for metal fabrication that you’ll need for successful outcomes. We’ll cover:
What are the processes of metal fabrication?
Components for metal fabrication
Painting, powder coating & e-coating
What are the processes of metal fabrication?
Metal fabrication includes a series of processes used to shape, cut, and assemble metal materials into final products or structures. Here are the main steps involved:
1. Cutting
Cutting is typically the initial step in metal fabrication, where metal is sliced into desired shapes and sizes. Techniques include:
● Shearing: Cutting straight lines using a shear machine.
● Sawing: Using saws to cut through metal.
● Laser cutting: A high-powered laser makes precise cuts.
● Plasma cutting: Using a plasma torch for cutting electrically conductive materials.
● Water-jet cutting: High-pressure water mixed with abrasive substance cuts metal.
2. Bending
Bending changes the shape of metal without removing any material. Methods include:
● Press-brake bending: Using a press brake to bending metal sheets.
● Roll bending: Creating curved shapes with rollers.
● Folding: Using a folding machine to bend metal at specific angles.
3. Welding
Welding is the process of fusing two or more metal pieces by melting them together. Common techniques include:
● MIG welding: Involves a wire electrode and a shielding gas.
● TIG welding: Uses a tungsten electrode along with a shielding gas.
● Stick welding: Involves a consumable electrode coated in flux.
● Spot welding: Joins metal pieces at specific points using pressure and an electric current.
4. Machining
Machining removes material from a metal workpiece to shape it. Processes include:
● Milling: Removing material with rotary cutters.
● Turning: Rotating the workpiece against cutting tools using a lathe.
● Drilling: Creating holes with a drill bit.
● Grinding: Using an abrasive wheel to remove small amounts of material.
5. Punching
Punching creates holes in metal sheets by applying a shearing force with a punch and die. This can be done using:
● Turret Punch Press: Equipped with various punch tools.
● CNC Punching: Using computer numerical control (CNC) machines for precision.
6. Stamping
Stamping presses metal sheets into specific shapes using a stamping press and dies. This process includes:
● Blanking: Cutting out shapes from metal sheets.
● Embossing: Creating raised or recessed designs.
● Coining: Stamping patterns or images into metal.
7. Assembling
Assembling involves joining various metal parts to create the final product. Methods include:
● Fastening: Using bolts, screws, or rivets.
● Adhesive Bonding: Applying industrial adhesives.
● Welding: Using welded joints for integration.
8. Finishing
Finishing processes enhance the appearance, durability, and resistance to corrosion of metal products. These processes include:
● Painting: Applying paint for protection and aesthetics.
● Powder Coating: Applying a dry powder that is cured under heat.
● Anodizing: Forming a protective oxide layer through an electrochemical process.
● Plating: Depositing a metal coating on the surface.
● Polishing: Smoothing and shining the metal surface using abrasives.
Components for metal fabrication
Metal fabrication relies on a variety of components to achieve precision, functionality, and durability in products. These components are essential for several reasons:
1. They enable the accurate assembly and integration of different metal parts, ensuring that the final structures or products meet stringent specifications and performance standards. Without these components, the fabrication process would lack the necessary flexibility and reliability required for complex constructions.
Other components for metal fabrication are vital for protecting metal parts from environmental factors, contamination, and physical damage during both the fabrication process and the product's lifecycle.
2. They ensure that open ends, joints, and threads are sealed against dust, moisture, and other contaminants, thereby prolonging the lifespan of the products and maintaining their integrity. Then there are components for metal fabrication that facilitate efficient and safe handling and manipulation of metal pieces during fabrication, enhancing both productivity and worker safety.
At Essentra Components, we can enhance metal fabrication processes with our comprehensive range of specialized components:
Painting, powder coating & e-coating
Masking processes in metal fabrication play a crucial role in protecting specific areas from treatments, ensuring that only the desired sections of the metal are exposed to the finishing process.
Vinyl pull caps
Protects specific areas from the finishing process. Their curved pull tab design offers more surface area, requiring less force for installation and removal. These caps are made from flexible PVC, allowing them to stretch for a snug fit without tearing. Max temperature: 350°F.
Easy-pull masking caps
Provides effective protection for various end-tip profiles such as rods, pipes, and tubes. They come in different styles, including versions with a flanged design and internal seal for a secure fit, plus options featuring ergonomic finger pull-tabs for easy removal. Available in silicone for high temp and chemical resistance (600°F) (316°C), EPDM for economical use with moderate heat resistance (425°F) (218°C), and soft PVC for economical single-use applications (425°F) (218°C).
Tapered paper plugs
Tapered masking plugs made from crepe paper and ideal for applications involving painting or powder coating. They can endure temperatures up to 400°F (204°C), providing a budget-friendly substitute for silicone. These caps and plugs are manufactured using a mix of post-consumer and virgin materials, making them environmentally friendly, as they’re recyclable themselves.
Thread protection plugs
Designed for masking both threaded and plain through holes. Apply by pulling the thinner end of the plug through the hole until the larger end stretches through, then release it to compress and create a tight seal. Flanged pull plugs are used to mask the backside of the hole. Available in high-temp silicone (316°C), cost-effective EPDM (218°C), and TPR.
Masking tubing
High-temperature tubing provides an effective masking solution for longer parts where standard caps may be too short. Supplied on a roll, the tubing can be cut to desired length. Can also be used to mask through-holes by pulling it through and using the outside diameter of the tube. Flexible silicone conforms to irregular shapes. Reusable, making it a cost-effective choice. Also available in EPDM.
Hooks
Offers robust support for handling loads. Designed for multiple uses, ensuring cost-effectiveness. The S-shaped design accommodates wider parts and various styles cater to different thicknesses, providing versatility. Also available: V, C, CV, free-hanging variations, and V 90-degree shapes. Cold-drawn spring steel and copper-drawn iron wire.
High-Temp Tape and Discs
Available in material options to suit different masking needs. All tape and discs are supplied with a split-back liner for easy removal from the role. Cleanly removed after use without leaving behind unsightly residue.
Flangeless tapered plugs
Designed to mask holes without covering the surrounding surface area. The tapered design protects multiple hole diameters. Ergonomically friendly profile push fits for easy installation. Available in EPDM (180°C), Silicone, TPE, and PVC.
Shipping Protection
Components are essential to prevent damage and contamination to applications during transportation and storage. This ensures that items arrive in optimal condition, maintaining their functionality, quality, and value, while reducing the risk of costly returns, repairs, and replacements.
Vinyl caps
Our extensive range of round vinyl end caps is made from PVC. This flexible material allows the caps to stretch over larger dimensions, ensuring a snug fit without tearing, splitting, or shredding. Typically used to protect threaded or non-threaded tubing, rods, pipes, or paper tubes. Their glossy and attractive finish also makes vinyl caps suitable as decorative end caps.
Threaded plugs Threaded o-ring plugs – metric thread
These threaded o-ring plugs for metric thread feature a compressed flange lip and o-ring to create a watertight seal, preventing leakage and keeping contaminants out. Ideal for applications in the oil and gas, plumbing, and automotive sectors, where leak-proof seals are essential for maintaining system integrity. HDPE.
Tapered caps and plugs – heavy duty
Our heavy duty range of tapered caps and plugs protect threaded and non-threaded pipes, ports, and access points from damage, dust, and debris during storage and shipping. Featuring a heavy-duty wall and a tapered sealing ring for maximum protection. These robust caps and plugs offer extra durability and a secure push-fit seal, withstanding impact and abrasion. LDPE.
Flexible protective netting
Adapts to various shapes, minimising labor costs, inventory needs, damage claims, and returns. Available on a roll in standard or heavy gauge for added durability. Ensures optimal visibility for workers and visitors while offering robust protection against potential hazards. Easy to apply and remove, does not retain moisture, and is commonly used in warehouses to safeguard against falling objects or debris.
Threaded protection caps
Threaded protection caps protect UNF/JIC threads and fittings from damage throughout production, storage, and shipment, ensuring they remain intact and operational when needed. Effectively blocks contaminants from entering flared and flareless holes. Featuring a knurled head design, these are easy to install and remove by hand, either by twisting or pushing onto pipes or tubes. Available in HDPE, LDPE, or nylonwith a long profile for extended threading turns.
Flange protectors
Full-face coverage and bore protection for high pressure applications. lugs insert securely into the flange bolt holes for a positive fit. Our range includes options that offer protection for SAE Code 61 (3000 to 5000 PSI) and SAE Code 62 (6000 PSI). Available in LLDPE, PE, LDPE, PP.
Cable mounting and wiring
Components designed for cable management play a crucial role in securing and organising cables, preventing tangling, strain, and potential damage. Each component here serves a specific function in routing, protecting, and maintaining the integrity of wiring and cables.
Flexible hole grommets
Protects wires, cables, tubes, and hoses from damage around panel holes or knockouts. Available in Styrene Butadiene (SBR) for standard sheet metal holes, with easy snap-in installation and excellent adhesion. Also available in standard and TPE. Standard PVC resists staining, ozone, acids, and sunlight, while TPE has a flame resistance rating UL 746C and is suitable for outdoor use.
Snap-fit bushings
Bushings protect wires, cables, and tubing from the sharp edges of drilled and pulled holes in sheet metal. Includes multiple locks for secure snapping into various panel thicknesses, facilitating effortless installation with just fingertip pressure. Tools not required. Nylon 6/6 and heat-stabilised nylon 6/6.
Cable conduit
Developed and tested to meet stringent quality standards, receiving global quality approvals and compliance certifications. Designed to support plastic conduit systems and accessories and offers exceptional flexibility and a long fatigue life. Its high impact strength enables recovery after crushing, while its self-extinguishing properties and high UV resistance ensure durability. Flame retardant with excellent resistance to solvents and oils. Available in split and unsplit.
Cable ties
Our vast offerings range from to belt cable ties to heat-stabilised locking cable ties, ideal for applications where heat is generated or present. Also available are push-mount heat-stabilised cable ties, which provides enhanced stability and durability in challenging environments.
Cable tie mounts
Four-way adhesive mounts provide extensive versatility for mounting options, supporting both adhesive and screw-mount holders. Adhesive back ensures strong adhesion for quick and effortless installation for lightweight wire bundles. Features a panel hole for optional screw fastening as well. Also available: heavy-duty cable tie mounts, metal cable tie mounts, and snap-in cable mounts.
Push-in rivets – snap
Cost-effective, arriving pre-assembled and ready to use. Features specially engineered legs that expand and securely lock components in place permanently. Good thermal and electrical insulation properties. Nylon 6, nylon 6/6, nylon 6/66 and heat-resistant nylon 4/6. P-type snap rivets made from black Polysulfide (PSU), with a UL94 HB rating, withstand temps up to 311°F.
Finishing
Our components are indispensable in finishing applications, ensuring the integrity, functionality, and aesthetic appeal of the final product. Below are examples that can help you achieve optimal performance for your application.
Round chrome tube inserts and glides
Designed for round tubing, providing a sleek and professional finish. Its horizontal ribs offer flexibility to fit various tube gauges, preventing floor damage and shielding the tube from external elements. LDPE.
Push-in rivets
These push-in fasteners are an efficient, quick solution for securely joining plastic, light sheet metal, insulating materials, circuit boards, or other thin materials. Offers strength and durability, making them ideal for connecting elements and technical components. Designed with legs that compress and expand to lock into pre-punched holes, while large heads facilitate easy assembly. Reusable and economical. Nylon 6/6.
Hand grips
Round finger-grasp grips are ideal for applications requiring a uniform finger grasp. Flexible and strong PVC material fits standard bar sizes on hand trucks, punch presses, tools, and other equipment.
Sheet metal plugs
Sheet metal plugs cover and protect holes in sheet metal. Easy to install, they snap into place to prevent debris, dust, and moisture from entering through the holes. Sheet metal plugs not only enhance the aesthetic appeal of the assembly but also contribute to its overall durability and functionality.
Clamping knobs
Clamping knobs, or hand knobs, are used for adjusting settings, clamping components, turning mechanisms, and tightening fixtures. Our range includes fluted knobs, star clamping knobs, T-handle clamping knobs, wing clamping knobs, and 3-arm and 4-arm clamping knobs. Available in durable materials like nylon, polypropylene, and soft-touch TPE.
Weld-on bullet hinges
Weld-on bullet hinges function as a lift-off hinge solution. Ideal for attaching metal doors to frames, providing both strength and aesthetic appeal. Especially suitable for narrow frames where other hinge types may be too bulky. Available in aluminum, steel, and stainless steel options, these hinges come with choices of brass, steel, or stainless steel pins and washers. Available with or without a grease nipple.
Quarter-turn spring latches
Quarter-turn latches are engineered to lock and secure panels and doors by rotating a cam, which engages with the frame or keeper on the backside. Operated using a key with a driver tool cylinder.Made of zinc alloy with a chrome-plated finish.
Pull handles
Front-mounted for ease of installation. Made from durable nylon, this handle is used where a sturdy grip and easy access are necessary, such as on doors, cabinets, or other panels.
Retractable spring plungers
Ideal for machining applications, serving as positioning tools, loading pins, alignment pins, and indexing devices. Offers a quick and convenient way to adjust or remove accessories on equipment, especially in limited spaces. The lock-out feature allows for two-handed adjustments by keeping the pin plunger in an open position, enabling hands-free operation. Steel with a clear zinc-plated finish. Resists corrosion.
Sealing gaskets
Clip-on profiles provide edge protection and sealing. Essentially used on metal sheets, they offer protection from vibrations, ingress of humidity and dirt. Often used as an additional seal to enclosure boxes. Available in EPDM and PVC.
Concealed hinges
Screw-on concealed hinges are available in handed, pin, removable pin, and spring-loaded types. Handed hinges feature a 90° rotation and reinforced multilink articulation for high rigidity and resistance to bending and twisting. Suitable for both left- and right-hand applications in light and heavy-duty use. The pin concealed hinge offers a 120° rotation and high mechanical strength, making them ideal for heavy-duty applications. Hinges with removable pins provide a 180° rotation, perfect for metallic enclosures.
Material handling
Toggle clamps play a vital role in material handling by securely holding workpieces or fixtures during manufacturing and assembly processes. Their quick and reliable clamping action ensures precise positioning, which is crucial for maintaining accuracy and quality in production. By preventing slippage and ensuring secure grip, toggle clamps enhance safety and facilitate efficient handling of materials.
Horizontal toggle clamps
These horizontal manual hold-down clamps feature a compact design with a cushioned PVC handle grip for user comfort. Their unique mechanism allows the handle and hold-down bar to move in opposite directions, ensuring a strong and secure holding capacity. The handle and arm linkage are designed to provide a smooth continuous action. Zinc-plated components for corrosion resistance.
Vertical hook & latch clamps
These light-duty manual toggle clamps are typically used in woodworking and joinery for securing and holding objects firmly in place. Features zinc-plated steel construction to prevent corrosion and an ergonomic PVC grip with a cushioned rib profile. Vertical latch pivot points are equipped with hardened steel or stainless steel rivets to ensure durability, accuracy, and a prolonged service life.
Manual push-pull clamps
Manual push-pull clamps with a base-type design secure materials by employing a plunger mechanism that ensures a direct, positive straight-line action. Their low-profile nature allows for side or end clamping, making them ideal for applications with limited vertical space.
Vertical toggle clamps
Designed to apply significant pressure while saving space. These manual hold-down clamps feature a cushioned PVC hand grip for comfort and durability. Pivot points are reinforced with hardened steel or stainless-steel rivets to maintain accuracy and ensure a long service life. Includes adjustable spindles and are designed with formed ends on the arms for efficient performance.
Toggle clamp accessories – spindle assemblies
Spindle assemblies are the parts of a toggle clamp that involve the spindle (the threaded rod or shaft) and its associated components. These assemblies can include various components such as nuts, handles, washers that are used to adjust the clamp's holding capacity or to replace worn or damaged parts. They play a crucial role in the functionality and versatility of toggle clamps, allowing users to customise or maintain their clamps according to specific needs or conditions.
Try before you buy
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Questions?
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