What materials are available for custom sheet metal fabrication?

We work with aluminum, stainless steel, carbon and galvanized steel, copper, brass, titanium, and specialty alloys. Grade selection is matched to forming, welding, finishing, strength, corrosion resistance, and cost requirements.

What sheet thicknesses and tolerances can you support?

It depends. Sheet thicknesses typically range from 0.1–12 mm, depending on material and process. Laser cutting can reach ±0.05 mm on suitable features; bending accuracy depends on bend-to-edge distance, angle, material, and springback.

What is the typical lead time for sheet metal parts?

As fast as 3 days for suitable prototypes and straightforward parts. Welding, hardware insertion, special finishes, tight inspection, or higher volumes may require longer.

Is there a minimum order quantity?

No. Mastars supports quantities from 1 to 100,000 units, from a single prototype to repeat production.

What CAD file formats do you accept?

We accept STEP/STP, IGES, DXF, DWG, and PDF. A CAD file and rough quantity are enough to start; add material, thickness, critical dimensions, finish, hardware, and weld requirements if available.

How much does custom sheet metal fabrication cost?

It depends. Material, thickness, cut length, bends, tooling, hardware, welding, finishing, tolerance, inspection, and quantity drive cost. Send your CAD files and rough volume for a project-specific quote.

Can you provide hardware insertion, welding, finishing, and assembly?

Yes. We support tapping, countersinking, PEM insertion, riveting, TIG/MIG/spot welding, deburring, grinding, finishing, and final assembly.

Do you provide sheet metal prototyping before production?

Yes. Prototypes help verify fit, assembly, bends, hole locations, hardware, function, and finish before repeat production.

Can Mastars support both low-volume and production manufacturing?

Yes. We support prototypes, low-volume and bridge production, repeat batches, and production volumes, adjusting the process as quantity changes.

How do you ensure sheet metal part quality?

We use drawing review, FAI, in-process checks, dimensional and CMM inspection, visual inspection, and final verification based on part requirements.

Sheet Metal Fabrication

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Services

3^Days

Fastest Lead Time

1⁺

No MOQ

±0.05^mm

Laser Cutting Accuracy

800⁺

Global Customers Served

Sheet Metal Fabrication Capabilities

Forming

Create ribs, beads, louvers, and other formed geometry where material flow and tooling affect repeatability.

Bending

CNC bending for flanges, returns, hems, and formed features, with bend angles around ±1° and bend-to-edge dimensions around ±0.25 mm, depending on material and geometry.

Punching

Efficient for repeated holes, slots, knockouts, and formed features at repeat production volumes.

Welding

TIG, MIG, and spot welding for housings, frames, and assemblies, with distortion and weld access reviewed upfront.

Laser Cutting

Fast, accurate cutting for brackets, panels, enclosures, and other flat parts, with cutting accuracy down to ±0.05 mm and sheet thicknesses from 0.1–12 mm depending on material.

Waterjet Cutting

Cold cutting for thick or heat-sensitive materials where avoiding a heat-affected zone matters.

Which Sheet Metal Process Is Right for Your Part?

Match the process to part geometry, material thickness, tolerance, heat sensitivity, feature repetition, and production volume.

Process	Best For	Material Options	Advantages & Trade-Offs	Typical Applications	What We Review Before Production
Laser Cutting	Flat parts with complex contours, holes, and slots; suitable sheet thicknesses from 0.1–12 mm depending on material	Aluminum, Stainless Steel, Carbon Steel, Brass, Copper	Flexible, low setup cost, and cutting accuracy down to ±0.05 mm on suitable features. Heat input becomes more important as thickness increases.	Enclosures, brackets, panels, prototypes, machine components	Thickness, minimum feature size, hole diameter, heat impact, edge condition, nesting and downstream bend locations
Sheet Metal Bending	Parts requiring flanges, folds, returns, hems, and structural features	Aluminum, Stainless Steel, Carbon Steel, Copper Alloys	Typical bend control can reach around ±1° angle and ±0.25 mm bend-to-edge, depending on material, bend length, and geometry.	Cabinets, brackets, frames, housings, chassis	Bend radius, grain direction, springback, flange length, hole-to-bend distance, bend sequence and tolerance
Sheet Metal Forming	Ribs, louvers, beads, drawn features, and more complex formed geometry	Aluminum, Steel, Stainless Steel, Specialty Alloys	Improves stiffness and can reduce assembly, but complex forming may require dedicated tooling and introduces thinning or deformation risk.	Covers, structural panels, industrial and transportation components	Formability, material flow, thinning, springback, tooling requirements and geometry feasibility
Sheet Metal Welding	Multi-part structures and fabricated assemblies	Steel, Stainless Steel, Aluminum	Strong permanent joints, but heat input can distort thin sections and may require fixtures, grinding, or post-weld correction.	Frames, equipment structures, cabinets, fabricated housings	Joint design, weld access, heat distortion, weld sequence, fixture strategy, cosmetic requirements and inspection
Sheet Metal Punching	Repeated holes, slots, knockouts, and standard features at repeat production volume	Aluminum, Steel, Stainless Steel	Faster and more economical as feature repetition increases, but dedicated tooling reduces flexibility for frequent design changes.	Electrical cabinets, panels, brackets, hardware components	Feature spacing, tool availability, thickness, distortion risk and production quantity
Waterjet Cutting	Thick or heat-sensitive materials requiring cold cutting	Aluminum, Stainless Steel, Steel, Titanium, Composites	No heat-affected zone and suitable for thicker stock, but generally slower than laser cutting and edge taper can increase with thickness.	Heavy equipment parts, aerospace parts, specialty components	Thickness, taper, edge quality, cutting speed, tolerance and secondary finishing

From Sheet Metal Prototypes to Production Parts

Sheet Metal Prototyping

Validate fit, assembly, function, and finish with real sheet metal before repeat production.

As Fast as 3 Days
1 Part, No MOQ
Fit, Bend & Assembly Checks
Production-Grade Sheet Metals
Design Changes Before Production Release

Explore Sheet Metal Prototyping

Sheet Metal Production

Scale validated designs around repeatability, quality, unit cost, and demand.

1–100K Units
FAI / CMM for Critical Features
Repeatable Bend & Weld Fixtures
Batch Supply to Limit Inventory
Process Matched to Volume & Unit Cost

Explore Sheet Metal Production

Custom Metal Fabrication for Complex Sheet Metal Projects

Some projects involve more than a cut-and-bend part. Machined inserts, PEM hardware, welded subassemblies, cosmetic finishes, critical mating surfaces, and final assembly can create risk at the interfaces between processes.

Mastars coordinates flat-pattern review, bend and hardware zones, weld access, fixture strategy, finish allowance, inspection datums, and assembly requirements under one project. Sheet metal can also be combined with CNC-machined, 3D-printed, molded, or cast components when required.

Get a Quote

Sheet Metal Tolerance & Precision Capabilities

Apply tight tolerances where function requires them; achievable accuracy varies with thickness, bend length, springback, heat input, tooling, and part geometry.

Process	Typical Tolerance	Key Factors Affecting Accuracy	Typical Applications
Laser Cutting	Down to ±0.05 mm on suitable features	Thickness, part size, heat input, hole/slot size and edge condition	Flat brackets, panels, enclosures, precision sheet parts
Sheet Metal Bending	Bend-to-edge around ±0.25 mm and bend angle around ±1°, depending on geometry	Springback, grain direction, bend radius, bend length, tooling and bend sequence	Housings, frames, brackets, chassis
Sheet Metal Forming	Drawing-specific	Material flow, thinning, springback, tool geometry and part profile	Formed panels, covers and complex 3D sheet components
Sheet Metal Welding	Assembly-specific	Heat input, joint layout, weld sequence, fixture design and post-weld correction	Frames, cabinets, welded housings and assemblies
Sheet Metal Punching	Typically ±0.1–0.2 mm	Punch-to-die clearance, tool wear, thickness, feature size and spacing	Panels, brackets and repeat production parts
Waterjet Cutting	Typically ±0.1–0.3 mm depending on thickness	Material thickness, kerf taper, cutting speed, abrasive and edge requirements	Thick plate, heat-sensitive and specialty components

Sheet Metal Materials

Choose sheet metal by formability, weldability, corrosion resistance, weight, finish, and cost—not strength alone.

Aluminum

Stainless Steel

Carbon Steel

Copper & Brass

Titanium

Specialty Materials

Aluminum

Aluminum is widely used for lightweight enclosures, brackets, panels, and structural sheet parts. Formability varies significantly between grades and tempers.

Key Characteristics

Low weight and good corrosion resistance

Good thermal conductivity

Easy to machine and finish

5052 and 3003 are well suited to bending and forming

6061 offers higher strength but generally needs larger bend radii, especially in T6 condition

2024 and 7075 require more careful forming review

Common Grades: 5052, 3003, 6061, 2024, 7075

Typical Applications

Electronics enclosures

Robotics structures

Aerospace brackets and panels

Automotive components

Industrial equipment

Available Finishes: As Fabricated · Bead Blasting · Anodizing · Powder Coating · Brushing · Painting

Stainless Steel

Stainless steel is selected when corrosion resistance, strength, cleanliness, and long service life are more important than low material cost.

Key Characteristics

Excellent corrosion resistance

High mechanical strength

Good weldability in common austenitic grades

304 offers a good balance of formability and cost

316/316L provides improved resistance in chloride environments

Higher-strength grades may require larger bend radii and more forming force

Common Grades: 304, 316 / 316L, 430, 17-4 PH

Typical Applications

Medical equipment

Food-processing equipment

Industrial machinery

Electrical enclosures

Marine and outdoor components

Available Finishes: Brushing · Polishing · Passivation · Bead Blasting · Powder Coating

Carbon Steel

Carbon and mild steels provide high stiffness, good weldability, and low material cost for structural sheet metal parts. Corrosion protection is normally required unless galvanized material is used.

Key Characteristics

High strength and stiffness

Cost-effective for structural parts

Good welding and fabrication behavior

Cold-rolled material offers better surface quality and thickness consistency

Hot-rolled material is economical for heavier structural applications

Requires coating or plating where corrosion is a concern

Common Grades: Cold Rolled Steel, Hot Rolled Steel, Mild Steel, Galvanized Steel

Typical Applications

Machine frames

Industrial equipment

Brackets and supports

Cabinets and enclosures

Welded assemblies

Available Finishes: Powder Coating · Painting · Black Oxide · Zinc Plating

Copper & Brass

Copper and brass are used where electrical conductivity, thermal performance, corrosion resistance, or appearance matters. Their softer surfaces also require careful handling during fabrication.

Key Characteristics

High electrical and thermal conductivity

Good corrosion resistance

Good formability in appropriate grades

Suitable for electrical, thermal, and cosmetic components

Visible surfaces may require additional scratch protection

Common Grades: Copper C110, Brass C260

Typical Applications

Electrical components

Busbars and conductive parts

Heat-transfer components

Connectors

Decorative hardware

Available Finishes: Polishing · Brushing · Plating · Clear Coating

Titanium

Titanium is used where high strength-to-weight ratio, corrosion resistance, or demanding environmental performance justifies higher material and fabrication costs.

Key Characteristics

High strength-to-weight ratio

Excellent corrosion resistance

Good temperature performance

Grade 2 provides better sheet formability

Ti-6Al-4V provides much higher strength but greater springback

Requires careful tooling and process planning

Common Grades: Titanium Grade 2, Ti-6Al-4V / Grade 5

Typical Applications

Aerospace components

Medical equipment

High-performance industrial parts

Chemical-processing components

Available Finishes: Bead Blasting · Polishing · Anodizing

Specialty Materials

Specialty materials are used when standard aluminum, steel, or stainless grades cannot meet spring, temperature, corrosion, or wear requirements.

Key Characteristics

Spring steel for elastic return and fatigue-resistant parts

Nickel alloys for demanding heat and corrosion environments

Coated steels for additional corrosion protection

Higher-hardness grades may require larger bend radii and greater forming force

Common Grades: Spring Steel, Nickel Alloys, Coated Steels, Tool Steel

Surface Finishing Options for Sheet Metal Parts

Finishing can affect final dimensions as well as appearance, so identify cosmetic faces, masked areas, threads, grounding points, and critical fits on the drawing.

Finishing Option	Result & Engineering Considerations	Suitable Materials	Typical Applications
As Fabricated	Lowest-cost functional condition. Cutting marks, bend marks, weld discoloration, or local grinding may remain visible.	Aluminum, Stainless Steel, Steel	Internal components, brackets, structural parts
Deburring & Edge Finishing	Removes sharp edges and burrs for safer handling and more reliable assembly.	Aluminum, Stainless Steel, Steel	Enclosures, machinery parts, assemblies
Bead Blasting	Produces a uniform matte texture and improves cosmetic consistency.	Aluminum, Stainless Steel, Steel	Visible housings and equipment components
Powder Coating	Durable protective coating with multiple colors and textures. Coating buildup can affect holes, threads, mating faces, and hardware seating.	Aluminum, Steel, Stainless Steel	Enclosures, industrial equipment, outdoor products
Painting	Provides flexible color and appearance control. Surface preparation affects adhesion and cosmetic consistency.	Aluminum, Steel, Stainless Steel	Product housings, prototypes, finished assemblies
Anodizing	Improves aluminum corrosion and wear resistance. Type II and Type III coating thickness must be considered around critical fits.	Aluminum Alloys	Electronics, robotics, aerospace components
Brushing	Creates a controlled directional grain. Grain direction should be defined for visible surfaces.	Stainless Steel, Aluminum	Electronics, appliances, visible panels
Polishing	Reduces surface roughness and can create reflective finishes. Material removal may affect sharp edges.	Stainless Steel, Aluminum, Brass	Medical equipment, decorative and visible parts
Plating	Adds corrosion resistance, wear resistance, conductivity, or appearance. Coating thickness affects threads, holes, and close fits.	Steel, Stainless Steel, Copper Alloys, selected Aluminum applications	Automotive parts, hardware, electrical components
Passivation / Chemical Conversion	Passivation restores corrosion resistance on stainless steel; conversion coating protects aluminum and improves paint adhesion with minimal dimensional buildup.	Stainless Steel / Aluminum	Medical, aerospace and precision components

Sheet Metal Fabrication Equipment & Inspection Capabilities

Production Equipment (Demo)

Process Control Equipment (Demo)

Inspection Equipment (Demo)

Sheet Metal Fabrication Project Showcase

Why Choose Mastars for Sheet Metal Fabrication?

Certified Quality Systems

ISO 9001, ISO 13485, and IATF 16949 certified processes help ensure consistent quality across industrial, medical, and automotive projects.

100+ Engineering Professionals

Work directly with experienced engineers for DFM reviews, tolerance recommendations, and manufacturing support—without unnecessary back-and-forth.

5+ Production Bases

Flexible manufacturing capacity supports both urgent prototypes and scalable production without single-site bottlenecks.

No Minimum Order Quantity

Order one part or thousands—without unnecessary volume commitments or tooling investments.

DFM Review on Every Order

Identify manufacturability risks early to reduce redesign cycles, save costs, and improve part performance before production begins.

800+ Customers Served

Trusted by global engineering teams across industrial equipment, medical devices, robotics, automotive, and consumer products.

Certifications

ISO9001:2015 Certificate

IATF16949:2016 Certificate

ISO13485:2016 Certificate

Medical A-Class Supplier

Partners

How Sheet Metal Fabrication Works

Upload Your Design

Share your CAD files, drawings, quantity, material, and any critical requirements.

Get an Engineer-Reviewed Quote

Receive pricing, lead time, and manufacturability feedback based on your part requirements.

Production Begins

Once you approve your quote, manufacturing starts — from prototype tooling to full-scale runs.

Parts Shipped

Finished parts are inspected, packaged, and shipped with the required quality documentation.

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