Online Custom Sheet Metal Fabrication Service

Sheet metal components and assemblies in as fast as 1 day. Get an online quote for your prototype or low-volume production project today.

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Certifications

ISO 9001:2015 | ITAR Registered

1,000+
parts within days
50,000+
Product developers served
37,000+
Parts fabricated each month

Sheet Metal Fabrication Capabilities

Our online sheet metal fabrication service enables you get a quote in minutes and have your parts delivered in days. We offer 3D visualized Design for Manufacturability (DFM) feedback to help you manage project costs and receive actionable design insights. With a broad range of fabrication and finishing capabilities, our powerful combination of technology and skilled operators produce precision quality parts whether your project has one component or many.

Laser Cutting

Laser cutting is a subtractive manufacturing process that uses a high-powered and focused laser beam to create precise cuts in sheet metal materials.

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Forming and Bending

Press brake forming uses a matching punch and die set and the application of force along a straight axis, producing linear bends on metal sheets.

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Punching

Punching is a process that combines a punch tool with a bottom die and uses a pressing force to cut part profiles and form metal sheets into specific shapes and patterns.

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Fabricated Assemblies

Sheet metal assemblies involve joining multiple sheet metal components through a variety of processes, such as welding or riveting, to create an assembled final product. 

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Sheet Metal Capability to Lead Time Map

Our online sheet metal fabrication service delivers components and assemblies to you in days. We offer a broad range of in-house fabrication and finishing capabilities to produce precision quality functional or end-use parts. 

Fabrication Capabilities Eligibility Applications
  • Cutting (laser or punch)
  • Deburring
  • Forming/bending (≤12 bends)
  • Hardware insertion (extensive PEM® library)
  • Tapping/countersinks

Material thicknesses:

≤0.125 in. (≤3.175mm)
  • Brackets
  • Covers
  • Panels
  • Flat geometries
  • Mounts
Fabrication Capabilities Eligibility Applications
  • All 3-day fabrication options plus CNC-machined features (pockets, flanges, other features)
  • Additional forming options (complex sequencing or setups, >12 bends)
  • Intricately formed features (hems, jogs/offsets)
  • Punch-formed features

All material thicknesses:

0.024 in. - 0.250 in. (0.61mm-6.35mm)
  • Complex internal componentry
  • Parts with features critical to quality or functionality
  • Enclosure or chassis housings
Fabrication Capabilities Finishing Options Applications
  • Welding (add 1 day)
  • Assembly (add 1-3 days)
  • Powder Coating (add 2 days)
  • Plating/coating (add 2 days)
  • Masking (add 1-2 days)
  • Silk screening (add 1 day)
  • Part marking (add 1 day)
  • Weldments
  • Multi-component assemblies
  • End-user-facing projects
Protolabs' Sheet Metal Fabrication Process Illustration

How Does Sheet Metal Fabrication Work?

During the sheet metal fabrication process, thin sheet metal stock is placed on a flat bed where a laser cutter (1) draws programmed part patterns. Depending on the part geometry, a sheet metal punch (2) can form additional features. Once the parts are deburred, they move to the press brake (3) where they are formed into the final geometries. Additional secondary operations are often used to finish the sheet metal parts.

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Advantages of Sheet Metal Fabrication

The sheet metal fabrication process is ideal for metal components and can support both prototyping and production quantities.

  • Low material waste
  • Can cost-effectively scale to production volumes
  • Multiple finishing options like anodizing and powder coating
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Our Sheet Metal Fabrication Process​

Unlike traditional sheet metal shops, we have infinite capacity and an easy-to-use online quoting system ensuring on-time shipment every time—whether you need a single part or 500 parts. You also have access to our team of knowledgeable engineers to optimize part designs and user-friendly online resources. Trim your production time and launch products faster with one local sheet metal supplier from prototypes to assemblies to finishing options.

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Design for Manufacturability (DFM) Feedback on Every Sheet Metal Quote

We now offer automated design analysis for all sheet metal components, which highlights any features that may pose challenges during the fabrication process. DFM feedback that can improve the quality of your sheet metal parts is now delivered in minutes.

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Sheet Metal Applications

Sheet metal is a versatile manufacturing process for a range of metal components. The process can support high-volume commodity products and low-volume, one-of-a-kind applications. Common sheet metal parts include:

  • Electrical enclosure
  • Parts for computer electronics
  • Chassis
  • Brackets
  • Cabinets
  • Mounts
  • Appliances

Our Sheet Metal Material Options

  • Aluminum(1)
  • Brass (2)
  • Copper (3)
  • Stainless Steel(4)
  • Steel: CR Non-treated (5)
  • Steel: CR Galvanneal and CR Galvanized (6)
AND
Aluminum 5052-H32
Aluminum 5052-H32
Formability
Corrosion Resistance
Weldability
Aluminum 5052 is a widely used alloy across common part applications made from sheet metal. This popular choice provides superior corrosion resistance, making it ideal for parts exposed to harsh environments. 5052 has a high modulus of elasticity, lending it to formability and weldability, allowing for unique shapes to be created out of the flat sheet. This material is versatile due to high strength, its lightweight nature, and aesthetic characteristics.
Tensile Strength
227.527 MPa 33 kpsi
Elongation
12%
Hardness
60 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.635mm to 6.35mm .025 in. to .250 in.
Example of Aluminum 6061-T651
Aluminum 6061-T651
Strength
Corrosion Resistance
Aluminum 6061 is also known as “structural aluminum.” 6061 is alloyed with silicon which provides higher strength capabilities than an alloy such as Aluminum 5052. 6061 has a lower modulus of elasticity compared to other options, making it less formable and weldable than 5052, but it maintains similar lightweight characteristics. The alloy composition of 6061 is designed to prioritize strength over aesthetics.
Tensile Strength
310.264 MPa 45 kpsi
Elongation
12%
Hardness
95 HRB
Max. Part Size:
990.6mm x 1193.8mm 39in. x 47 in.
Thickness Range:
.635mm to 6.35mm .025 in. to .250 in.
Sample of Brass C260
Brass C260
Aesthetics
Formability
Corrosion Resistance
Brass C260 is primarily composed of copper and zinc, giving it the golden-yellow color for which it is known. Mechanically, Brass has corrosion-resistant and formable qualities similar to Aluminum 5052. Brass is heavier than aluminum, making it well suited for aesthetic or decorative applications.
Tensile Strength
427.475 MPa 62 kpsi
Elongation
25%
Hardness
70 HRB
Max. Part Size:
457.2mm x 609.6mm 18 in. x 24 in.
Thickness Range:
.635mm to 3.175mm .025 in. to .125 in.
Sample of Copper C101
Copper C101
Electrical Conductivity
Thermal Conductivity
Formability
Copper 101 (C101) is known as oxygen free electronic or OFE Copper. It is primarily chosen when material impurities are undesired and electrical conductivity is crucial. It offers strong corrosion resistance and formable qualities but is more costly than oxygenated Copper 110. C101 is typically used for applications where exceptional conductivity is favored over cost savings.
Tensile Strength
282.685 MPa 41 kpsi
Elongation
14%
Hardness
40 HRB
Max. Part Size:
457.2mm x 609.6mm 18 in. x 24 in.
Thickness Range:
.813mm to 3.175mm .032 in. to .125 in.
Sample of Copper C110
Copper C110
Cost Effectiveness
Corrosion Resistance
Thermal Conductivity
Formability
Copper 110 (C110) is the oxygenated relative of Copper 101. Containing only a small amount of oxygen, C110 is more widely used for practical applications such as heat exchangers, wiring, and plumbing components. C110 is more readily available and is a lower cost copper option without trading off the formability characteristics of C101. While a strong electrical conductor and corrosion resistor, C110 contains impurities in the form of oxygen which can’t stand up to the purity of C101.
Tensile Strength
282.685 MPa 41 kpsi
Elongation
14%
Hardness
40 HRB
Max. Part Size:
457.2mm x 609.6mm 18 in. x 24 in.
Thickness Range:
.635mm to 3.175mm .025 in. to .125 in.
Sample of Low Carbon Steel CR 1008
Low Carbon Steel CR 1008
Formability
Weldability
Cost Effectiveness
Strength
Durability
Low Carbon Steel 1008 is a mainstay material option in sheet metal fabrication. Containing less than .30% carbon, 1008 is formable, not prone to cracking, and its minimal carbon content provides weldability without the brittleness of a high carbon option. 1008 comes uncoated from the mill and is susceptible to corrosion, however it readily accepts coatings and finishings (such as zinc or powder coat) for protection.
Tensile Strength
344.738/448.159 MPa 50/65 kpsi
Elongation
20/30%
Hardness
63-80 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.609mm to 6.35mm .024 in. to .250 in.
Sample of CR Galvanized Steel
CR Galvanized
Formability
Pre-Plated
Cost Effectiveness
Strength
Durability
Cold-Rolled Galvanized steel arrives from the mill with a zinc coating which prevents corrosion and provides its distinctive shiny, spangled appearance. This unique surface appearance makes it more challenging for other finishes, like powder coating to adhere to the metal without additional material preparation. This material lacks weldability due to fumes from its zinc coating, however galvanized is easily formed in the press brake.
Tensile Strength
365.422 MPa 53 kpsi
Elongation
36%
Hardness
50-65 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.609mm to 3.403mm .024 in. to .134 in.
Sample of CR Galvannealed Steel
CR Galvannealed
Formability
Pre-Plated
Cost Effectiveness
Strength
Durability
Cold-Rolled Galvannealed steel differs from galvanized due to receiving heat treatment and annealing after a zinc coating is applied. This additional process transforms the zinc coating to a zinc-iron alloy, providing corrosion resistance and low shine. The difference in surface finish appearance allows for better paint adhesion, however similar issues remain in terms of weldability. Both pre-plated steels offer strong formability characteristics.
Tensile Strength
344.738 MPa 50 kpsi
Elongation
37%
Hardness
50-65 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.609mm to 3.403mm .024 in. to .134 in.
Sample of Stainless Steel 304/304L
Stainless Steel 304/304L
Formability
Weldability
Corrosion Resistance
Strength
Durability
Stainless Steel 304 comes in two varieties, 2B and #4. These identifiers refer to the surface finish applied at the mill, but the underlying material is the same. 2B has a low shine appearance, whereas #4 has a brushed aesthetic from a mechanical polishing process. 2B typically costs less than #4, however both are formable and weldable. Of note, welding 304-#4 can remove the desirable brushed finish. 304 provides only adequate corrosion resistance and is particularly risky in high-chloride environments such as saltwater or coastal regions.
Tensile Strength
586.054/551.581 MPa 85/80 kpsi
Elongation
55%/55%
Hardness
70 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.609mm to 6.35mm .024 in. to .250 in.
Sample of Stainless Steel 316/316L
Stainless Steel 316/316L
Formability
Weldability
Corrosion Resistance
Strength
Durability
Stainless Steel 316 is similar to 304 but is instead alloyed with molybdenum. This feature enhances its corrosion resistance, especially in high-chloride marine environments. 316 has similar strength characteristics to 304 and is equally formable and weldable. Thanks to the addition of molybdenum, 316 is versatile, but comes at a higher cost than 304.
Tensile Strength
579.16/537.791 MPa 84/78 kpsi
Elongation
60%/55%
Hardness
79 HRB
Max. Part Size:
990.6mm x 1193.8mm 39 in. x 47 in.
Thickness Range:
.609mm to 3.403mm .024 in. to .134 in.
There are no materials that match the selected combination of filters.

Why Choose Protolabs for Sheet Metal Parts?

Fast and Simple Online Quoting

Our easy-to-use interface offers an average one-day upload-to-quote lead time (simple design quoting in as fast as one hour). Easily configure part specifications like material selection, and finishing options.

Reliable Delivery 

Quality parts delivered within our five-day standard lead time. 

Expansive Capacity

With more than 200 machines all under one roof, we’re dedicated to continuously evolving our capabilities.

Domestic Production

All sheet metal parts are made in New Hampshire with secondary operations such as hardware placement, welding, and finishing done in-house or locally by an approved vendor.  

Sheet Metal Technical Expertise

Work with our team of engineering experts that offer technical design guidance and can inform you on manufacturability and cost-saving opportunities.

Sheet Metal Finishing Options

Looking for more than a few basic sheet metal parts? We offer welding, hardware insertion, plating, silk screening, and powder coating to provide complete sheet metal components all under one roof.

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Sheet Metal Surface Finish Guide

Check out our sheet metal guide for a quick snapshot of our Standard and Cosmetic finishing options available for various sheet metal materials.

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