Steel Cutting Blog

As dawn breaks, the factory springs to life. A raw, unassuming sheet of steel lies on the shop floor. It will soon undergo a remarkable transformation.  

The day’s work is to create a complex engine cover, a piece vital for protecting sensitive machinery. The operator uploads a CAD file, a digital blueprint detailing the intricate design. With a hum that fills the air with anticipation, the laser cutter springs into action. Sparks fly as the laser, its beam slices through the steel with surgical precision. 

Within minutes, what was once a featureless steel sheet is now a perfectly shaped, smooth-edged engine cover, ready for the next stages of fabrication. 

It’s an example of the marvel of modern manufacturing—a piece that began as an idea, transformed into reality by the precision of laser cutting and the skilled hands of operators. 

This transformation, from raw materials to essential components, is repeated countless times across the industry every hour of every day. 

In this article, we’re looking at the world of industrial laser cutting for sheet metal fabrication, exploring how this technology offers many advantages over traditional methods—focusing on its speed, cost-effectiveness, and material utilization. 

If you’re interested in learning more about steel cutting or have a project in mind, reach out to Amber Steel. We’re always one email or phone call away.   

Sheet Metal Fabrication Step-By-Step 

Through cutting, forming, joining, and finishing, sheet metal fabrication offers limitless possibilities for creating everything from everyday items to specialized industrial components. 

1. Cutting 

The first step in sheet metal fabrication is cutting, where the metal is shaped into the initial outline needed for further processing. And that’s where Amber Steel comes in:  

1. A sheet of metal is placed on the cutting table inside the laser cutter. This table is grid or slat-based to allow the laser and any molten material to pass through without damaging the machine. 

2. The specifications for the cut are programmed into the machine’s control system. This includes the shape, dimensions, and cutting path based on digital designs, usually provided in CAD files. 

3. The laser beam is focused to a fine point at the cutting head, which concentrates the laser’s energy on a very small area of the metal, heating it up extremely quickly and melting or vaporizing it. The cutting head moves over the metal sheet along the programmed path.  

4. For thicker sheets or more complex cuts, the laser may make several passes to ensure clean cuts through the material. 

5. Once the cutting is complete, the finished pieces are removed from the sheet. The skeleton of the unused metal is also removed from the cutting table. 

Laser cutting uses a highly focused laser beam to melt and cut the metal, offering remarkable precision. Because of its accuracy and smooth finish, laser cutting is ideal for detailed or intricate cuts. 

To learn more about the basics of the laser cutting process, check out our post on Industrial Laser Cutting vs. Traditional Cutting Methods.  

2. Forming 

After being cut to size, the metal is shaped into the specified form. Depending on the components involved, the forming stage may involve a combination of bending, stamping, and/or rolling. 

• Bending: Creating angles and curves by manipulating metal sheets with mechanical force. Bending is done with various tools and machines, including press brakes, which press down on the metal to bend it at the desired angle. 

• Stamping: Stamping uses dies and high pressure to shape or cut the metal into a specific form. This process is used for high-volume production where the same shape is needed many, many times over. 

• Rolling: Metal sheets are passed through rollers that gradually form them into curved shapes or cylinders. Rolling is essential for creating components like tubes, tanks, and other rounded metal items. 

3. Joining 

After forming, the pieces must be joined to create more complex structures or final products. Welding is the most common method of joining metal pieces. Riveting, which is less common, does not involve melting but rather uses metal pins (rivets) to join two pieces of metal mechanically. It's a strong, durable joining method that doesn't affect the metal's integrity with heat. 

Adhesive bonding using a strong glue, or other adhesives is a third option. It's useful for joining dissimilar metals, or where heat might damage the components (and riveting isn’t an option.) 

4. Finishing 

The final step in sheet metal fabrication is finishing. This can include sandblasting to provide a textured finish that adheres well, painting, or plating with chrome or zinc. 

Why Choose Laser Cutting for Sheet Metal Fabrication? 

Laser cutting is the go-to choice for sheet metal fabrication, especially in precision-driven industries like automotive and aerospace. 

Faster Production Times 

Laser cutting speeds up the production process significantly. This machine is fast when it comes to cutting, and it also reduces setup times. With laser cutting machines, switching between different designs is a breeze. There’s no need to swap out physical tools or dies, which means we can go from one design to another in no time.  

Unmatched Precision and Quality 

One of the biggest advantages of laser cutting is its precision. The laser can achieve cuts and details so fine that other methods simply can't match. This high level of accuracy ensures that parts fit perfectly in subsequent assembly stages, reducing or even eliminating the need for further machining. That means faster production from start to finish. 

Less Waste, More Savings 

Laser cutting is incredibly efficient in terms of material use. The laser beam is so precise that it minimizes excess cut, maximizing the number of parts that can be created from a single sheet.  

Lower Labour Costs 

Thanks to laser cutting's automation capabilities, fewer hands are needed on deck. This helps reduce costs and minimizes human errors, leading to a smoother, more efficient production line. 

Plasma cutting is also a viable option for sheet metal fabrication. In general, it is a cheaper and easier process than laser cutting, and can be carried out with a handheld device. To learn more about plasma cutting, read our post on How Plasma Cutting Works & Its Advantages. 

Is it Worth Outsourcing Laser Cutting for Sheet Metal Fabrication? 

Sheet metal fabrication involves a lot of steps, from cutting all the way to finishing. You might wonder why we choose to specialize exclusively in laser cutting instead of handling the entire process.

There are good reasons for that: 

• We pour all our efforts and resources into the cutting process, a specialization that leads to unmatched efficiency and quality. By concentrating solely on cutting, we've invested in the latest technologies and attracted skilled operators who are serious about their craft. This means that when you trust us with your cutting needs, you're benefiting from top-tier expertise that's hard to find elsewhere. 

• Specialization allows us to work more efficiently, which translates into lower costs for you. We can achieve economies of scale, optimize our resource use, and maintain lower overhead costs than companies that try to cover every stage of fabrication.  

• Outsourcing laser cutting allows you to scale up or down production without adjusting your workforce or investing in new equipment.  Our operation is designed to adapt quickly and efficiently, meeting your needs, whether they spike unexpectedly or grow over time. 

Our approach not only ensures excellence in the parts we produce but also supports the overall success of your projects by allowing you to focus on your core competencies while leaving the intricate cutting details to us.  

Let Amber Steel Handle Your Sheet Metal Cutting 

At Amber Steel, our 72-inch wide laser cutter means we can handle larger sheets of metal than most. We’re not stuck on standard sizes. It’s great for making big parts or getting the most out of each sheet.  

And as discussed, our focus on specialized laser cutting means we deliver high-quality parts efficiently and effectively. We’re here to provide the precise cuts and quick turnaround times that our clients depend on. Amber Steel is more than equipped to support your projects and keep things moving smoothly.  

So, if you’re looking for a reliable partner in the steel fabrication industry, consider how Amber Steel can help you achieve more with your projects. Whether you need large-scale production or specific custom parts, we’re equipped to deliver exactly what you need. 

Learn more about steel cutting by contacting us today. Or, reach out with an email or phone call if you have a project in mind and wish to discuss it with industry experts.  

All industrial projects have one thing in common: they necessitate a significant financial investment. 

Even if, hypothetically, the upfront costs of shipbuilding or construction ventures (for example) are relatively frugal compared to industry standards, the dollar amounts involved would still be nothing to scoff at. 

For instance, the cost range to build an industrial facility can jump to $180 per square foot and beyond, depending on complexity.  

Modern cruise ships cost up to $900 million on average to build. On the lower end, it’s $500 million. 

These investments can seem daunting, even when you’ve made financially savvy decisions. However, these projects often yield returns far exceeding those upfront costs — provided both strategy and execution are sound. 

Part of sound strategy and execution is ensuring all facets of these projects optimize mechanical and financial efficiency. 

On the above note, metal fabrication and steel cutting are crucial in heavy industrial projects, from shipbuilding and construction to precision engineering and aerospace. It’s a foundational component ensuring robust stability and reliability — responsible for providing the bones of all structures. 

This brings us to flame cutting, which is aimed at the most robust industrial metals and materials.  

With flame cutting, mechanical efficiency is at the forefront, requiring only one pass to slice through 270mm-thick steel. There’s also the benefit of cost-effectiveness. Its economic implementation of gas and oxygen makes it ideal for many projects. 

There’s a caveat with flame cutting, though — that being quality control.  

Not all flame-cutting services are created equal, and the margin for error in heavy industrial applications is virtually non-existent. You can’t afford low-quality work on your projects.  

At Amber Steel, our flame-cutting services are second to none. Our expert technicians have mastered their craft, and our technology is state-of-the-art.  

These benefits combine to ensure the work is completed efficiently, cost-effectively, and of the highest quality. We employ a consultative approach centered around your needs as a client, tailoring our steel fabrication solution to what will most benefit your project and budget. 

Ensuring Flame Cutting Meets Your Project's Requirements 

We’ll open this section with a disclaimer: flame cutting has specific applications and limitations, typically beginning and ending with thick, heavy-duty metals.  

Using flame cutting for thin metals in situations calling for high levels of precision won’t generate the desired results.  

Thus, the prerequisite for quality control is ensuring flame cutting suits your project. 

When you apply flame cutting in the incorrect scenario, all the other quality control measures in the world mean nothing because the work is doomed to disappointment. The method and technicians involved aren’t being set up for success. 

Below, we’ll discuss the factors in choosing the correct cutting method, your first step in ensuring quality control. 

Metal Thickness 

Thin metals are not suited to flame-cutting — waterjet and hand-cutting methods are more suited to such projects. 

Conversely, the robustness of flame cutting is far more suited to thicker metals (although, depending on other factors, you might be better off choosing plasma cutting). 

Metal Type 

Aluminum is a softer metal, typically better suited to abrasive methods and hand tools. Alternatively, low alloy steels, cast irons, and carbon steel respond best to flame cutting. 

Weigh your metal type's hardness, thickness, and conductivity before determining the best flame-cutting method for your project. 

Accuracy Requirements 

In many aerospace applications, minimal distortion and high accuracy are paramount — in which case, flame cutting won’t fit. 

Construction work offers more wiggle room with accuracy-based needs. You don’t need to be ultra-precise, often making flame cutting the ideal choice for these projects (in no small part due to its cost efficiency).  

Cost Efficiency 

Some metals demand a high-cost cutting solution — otherwise, the job won’t be done correctly.  

However, many projects involve materials suited to more cost-effective and budget-friendly solutions like flame cutting. 

Overspending on a steel-cutting solution might yield an excellent final product but in a financially damaging fashion. Quality control is rendered useless if you’re getting raked over the coals because you’ve invested in a service that devours your budget when you could’ve chosen something more affordable that would’ve delivered equal results. 

How Fast Does It Cut? 

Manual and laser cutting are more suited to low-volume custom work.  

However, robust high-volume jobs with thick steels—calling for fast turnaround times — will benefit from the speed and efficiency of flame cutting. 

These factors can all be complicated to weigh on your own. So, consult with an industry expert who fully grasps your project's scope, materials, and spending limitations before deciding whether flame cutting fits your project. 

If flame cutting is the ideal choice, the rest of the quality control measures we discuss will come into play. 

Quality Control Measures Enhance the Benefits of Flame Cutting 

Here are the pivotal benefits of choosing flame-cutting services for your project: 

• Flame cutting bucks against industry trends of rising costs, primarily using gas and oxygen, offering a cost-effective solution that helps yield optimal returns. 
• As discussed, flame cutting’s ability to cut through heavy metals is unrivalled. Heavy industrial applications calling for raw power benefit tremendously from the speed and efficiency of flame cutting. 
• While flame cutting has limitations, its applications reach across many industries and applications. You’d be surprised at how often you’ll have a chance to leverage this technique’s cost-effectiveness and efficiency.  
• Because of their scalability and versatility, many opportunities to leverage flame-cutting services exist. One-time projects and larger-scale productions alike benefit from the flexibility of flame-cutting services, which will maintain quality and precision from beginning to end. 
• Flame-cutting equipment boasts heightened simplicity compared to other industry techniques. Thus, it’s often the practical choice, highly accessible, and seamless for clients needing a streamlined, efficient steel-cutting solution. 

These are significant benefits that can bolster a given project. Yet, everyone can fly out the window without the appropriate quality control measures. 

Quality control must be one of the top priorities of your flame-cutting service provider.  

When your steel-cutting partner is rigorous about ensuring the utmost quality, they maximize the benefits and neutralize potential pitfalls.  

Quality Control is also a Matter of Safety 

Safety is crucial for the types of construction projects calling for flame-cutting services. 

First and foremost is the human element of keeping workers safe. You don’t want anybody’s well-being at risk on a job site. 

There are also legal and financial ramifications when someone gets hurt, damaging your reputation and bottom line. 

On the above notes, flame-cutting machines possess high-temperature flames and involve combustible gases. Protective gear, adequate ventilation, and safety protocol adherence are vital.  

When these factors aren’t managed properly, it puts workers at risk. Safety flies out the window. 

Furthermore, flame-cutting service providers who don’t prioritize safety are telling you a lot about the rest of their quality control practices. The well-being of labourers and technicians doesn’t matter to such a company. Then, they probably don’t care too much about the quality of their final product, either. 

What Factors Dictate Quality in Flame Cutting? 

The value of quality control can’t be overstated as it pertains to flame cutting.  

Investing in a flame-cutting service with rigorous quality control measures ensures optimal value for dollars spent and a top-notch final product. 

Still, it’s worth asking: What are the parameters of “quality” in relation to flame cutting? We’ll answer in the bullet points below: 

• The cutting speed is optimized by the fuel gas chosen, which should either be acetylene-oxygen or propane oxygen mixtures.  
• Flame temperature also impacts cutting speeds. The higher the temperature, the quicker the ideal ignition temperatures are reached.  
• Acetylene-oxygen mixtures reach a 3160 °C flame maximum temperature, ensuring optimized cut speeds at affordable prices.  
• The optimum distance between the workpiece and nozzle helps ensure high-quality cutting, as does high oxygen pressure. 

These are critical factors in ensuring high-quality results from your flame-cutting service provider. Industry leaders will stop at nothing to ensure you get nothing but the best. They’ll be rigorous about quality control measures to ensure each cut follows the parameters detailed above. 

Ensuring Your Flame Cutting Service Partner Prioritizes Quality Control 

Investing in a partnership with a steel-cutting service provider is a significant decision for your project. 

Your choice of who to work with will depend on your vetting through prospective service providers and third parties, determining who best fits your needs. 

Due diligence will be your guide. This means looking up online reviews, requesting references and portfolios of work from prospective partners, and seeking testimonials.  

Time might be of the essence to get your project underway, but your choice in flame-cutter shouldn’t be rushed.  

Find out how prospective partners will ensure quality. Investigate if they’re committed to offering you the most value and providing the best results for your project or merely trying to sell you something. 

At Amber Steel, our clients and the needs of their projects come first.  

Speak with us as a prospect, and we’ll provide expertise and insights that inform you of the quality of our work and the best ways to proceed with what you’re doing. 

Contact us today If you’re seeking flame, plasma, or laser-cutting services and wish to consult with one of the industry’s foremost leaders.