Choosing the right cutting method shapes cost, throughput, and finish. Material grade, thickness, geometry, and batch size all matter. Good results in sheet metal fabrication come when precision, speed, and downstream behaviour are weighed together.
Mechanical Shearing and Punching
Mechanical routes suit simple outlines and high volumes. Shearing gives fast, straight cuts, while punching adds holes and profiles once tooling is proven. The trade-off is flexibility and tolerance, as design changes can mean new dies, burrs may need dressing, and tight radii or complex shapes push limits.
Laser Cutting
Laser suits intricate features and short lead times. Programming is quick, kerf narrow, and repeatability strong on thin to medium sections, aiding forming and assembly. Heat can influence edges on alloys, thick plate slows progress, and reflective metals may need sources and extraction to control fumes.
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Waterjet Cutting
Waterjet is a cold process that protects metallurgy and preserves edge quality, especially on thicker stock or heat-sensitive materials. It handles many metals and non-metals and follows complex contours with minimal secondary work. Running costs rise with pumps and abrasive, thin sheets can cut slower than laser, and accurate fixturing with taper control supports tight tolerances.
Plasma Cutting
Plasma brings speed on mid to thick conductive plate and suits structural profiles where throughput matters. Consumables are affordable and productivity is high. Edges are rougher than laser or waterjet, tolerances looser, and the heat-affected zone plus fumes require control via extraction and timely maintenance.
