A Guide to Metals and Metal Manufacturing
Content in this Article
Metal Fabrication cannot be selected from the highest datasheet value alone. Service temperature, load, chemical exposure, process and inspection method define the practical shortlist.
- Define function, environment, quantity and risk before selecting a material or process.
- Treat typical values as comparison points; confirm the exact grade and supplier capability before release.
- Use a first article or pilot lot to verify dimensions, function and records before scaling.
Define the decision
Document function, environment, quantity and risk so every option is compared against the same requirement.
The Alloy Families Worth Knowing by Reflex
| Alloy | Why it is chosen | Push elsewhere when |
|---|---|---|
| 6061-T6 aluminium | General-purpose structural; machines and anodises well | Fatigue-critical cyclic loading; coastal salt exposure |
| 7075-T6 aluminium | Higher strength than 6061, aerospace default | Outdoor / humid; cost-sensitive; weldability required |
| 5052-H32 aluminium | Formable sheet for bending and drawing | Need machining or high strength |
| AlSi10Mg (cast / LPBF) | Printable and castable aluminium workhorse | High-cycle fatigue above 10^7 cycles |
| 1018 / 1045 carbon steel | Cheap, machinable, weldable mild/medium carbon | Corrosive environment without finishing |
Metal Fabrication evaluation flow
Define requirements, narrow the material and process, then verify with a consistent acceptance method.
- 1Requirements
Function, environment, quantity and risk
- 2Options
Material, process, design controls and finishing
- 3Acceptance
Dimensions, functional tests and production records
Compare the practical options
Compare material, process, design controls and finishing together—not unit price alone.
Three Metal Choices That Changed Outcomes
Unit-cost premium was 3. 3×; lifecycle cost dropped by an order of magnitude because the next recovery mission never needed to happen on schedule.
Validate before scaling
Before scaling, verify dimensions, function and records with one controlled method across representative lots.
A Cost Anchor Across the Main Routes
| Route | At 1 unit | At 100 units | At 10,000 units | Tooling cost |
|---|---|---|---|---|
| CNC 6061-T6 | 380 – 580 | 180 – 290 | 120 – 190 | 0 |
| Sheet-metal 5052 | 220 – 340 | 90 – 160 | 45 – 95 | 0 – 1,500 fixture |
| Die-cast AlSi10Mg | N/A | N/A | 8 – 22 | 25,000 – 120,000 |
| Investment-cast 17-4 PH | 1,400 – 2,200 | 380 – 620 | 90 – 180 | 18,000 – 45,000 |
| LPBF AlSi10Mg | 480 – 820 | 360 – 540 | 320 – 450 | 0 |
Read the table with volume in one hand and lead time in the other. Below a hundred units the premium of subtractive or additive routes barely registers against tool-amortisation; above ten thousand, casting and stamping dominate so completely that other routes only survive on geometry or service justification.
Pre-RFQ review: recommended practice and common mistakes
| Recommended practice | Common mistake |
|---|---|
| Document function, environment, quantity and risk | Select from a material name or machine specification alone |
| Review material, process, design controls and finishing together | Address manufacturing limits only after design freeze |
| Inspect critical dimensions and function on the first article | Scale production from visual approval alone |
| Keep material, revision and inspection records | Reuse old results after a material or process change |
- Function, environment, quantity and risk are documented
- Material, process, design controls and finishing are reviewed with the supplier
- Critical dimensions, appearance and functional acceptance are on the drawing or RFQ
- First-article or pilot-lot verification is planned
- Material, process and revision changes trigger a new review
FAQ, further reading and sources
What should be defined first for Metal Fabrication?
Start with function, environment, quantity and acceptance criteria. These inputs narrow the practical options faster than naming a machine or material first.
Can typical values in this article be released directly on a drawing?
No. Use them for early comparison, then confirm the exact grade, supplier capability and first-article result.
When is the process ready to scale?
Scale only after material, process, finishing and inspection are controlled and repeatable across representative lots.
Next, explore 3D printing services, CNC machining, materials, and the related reports linked on this page.
