Sheet metal fabrication techniques are the backbone of how raw metal sheets are transformed into parts used in automotive bodies, consumer electronics, HVAC units, brackets, and more.

But if you’re a design engineer, sourcing manager, or technical buyer. Knowing which fabrication method to choose, and when, isn’t always straightforward. In this guide, we’ll break down three widely used sheet metal fabrication processes: folding, CNC machining, and deburring. You’ll learn.

• How each method works.
• Their advantages and drawbacks.
• When it makes the most strategic sense to use the sheet metal fabrication techniques.

 

What Is Sheet Metal Fabrication?

Sheet metal fabrication is the process of transforming flat metal sheets into usable parts or assemblies through cutting, bending, machining, joining, and finishing.

Depending on the part design, sheet metal thickness, and tolerance requirements. Fabricators use different techniques to shape and assemble components. These are known as sheet metal fabrication techniques. Choosing the right one largely depends on what you're building and how it's intended to be used.

Common Sheet Metal Manufacturing Methods

The main sheet metal fabrication techniques include:

1. Cutting: Laser, plasma, waterjet, or mechanical (sawing, shearing).
2. Forming: Bending, folding, stamping, rolling.
3. Machining: CNC milling, turning, drilling.
4. Assembly: Welding, riveting, screwing.
5. Finishing: Deburring, powder coating, anodizing.

Now let’s explore three of the widely used techniques that we often come across through our custom manufacturing platform.

1. Folding (Folding Metal Sheet Without Heat)

Folding is a metal forming technique that allows you to bend sheet metal without the need for heat. It’s especially useful when you need clean, consistent angles in flat parts. Most fabricators use press brakes or CNC folders to carry out the bending process. These machines are capable of creating sharp angles, like a 90 degree corner, in a matter of seconds. Depending on the part complexity and production scale, folding equipment may be manually operated or fully automated using CNC control.

Advantages	Disadvantages
High-speed processing	Sharp bends may cause material fatigue over time
No heat = no thermal distortion	Not suited for round or compound curves
Great for rectangular or boxy designs	Requires flat sheet stock to begin with
Works well for panels, brackets, and chassis

 

When to Use Folding

You can use folding when creating enclosures, panels, or support frames that require clean and repeatable bends. It’s particularly effective with materials like aluminum or stainless steel. This method is ideal for medium to high-volume production, especially when speed and consistency are priorities.

2. CNC Machining

CNC machining is a subtractive manufacturing process used to shape sheet metal by cutting away material with high-speed rotating tools. It’s commonly used to add features like threaded holes, slots, or grooves. Especially when precise placement or tight tolerances are needed.

Fabricators typically use computer-controlled mills or lathes to move cutting tools across multiple axes. This enables the cutting tools to generate repeatable, high-accuracy results even when the part has complex geometries.

Advantages	Disadvantages
Extremely precise, tight tolerances (±0.01 mm)	Slower than forming or stamping for high-volume runs
Complex geometries possible	Produces more waste than forming methods
Compatible with many materials: steel, brass, copper, aluminum	Requires longer setup and programming time
Ideal for prototyping and production alike

When to Use CNC Machining

Use CNC machining for parts that require tight tolerances, multi-surface features, or thread inserts. It’s also ideal for hybrid parts that are formed and then precision-cut.

3. Deburring

So what is deburring? Deburring is the process of removing small, sharp edges, called burrs, that form on metal parts after machining, laser cutting, or punching. These raised edges can interfere with part assembly, reduce surface finish quality, and even pose safety hazards during handling.

Depending on the part and production volume, burrs may be removed manually with files or abrasives, or with automated equipment like vibratory deburring machines and tumblers. Deburring is a standard post-processing step across most metal fabrication workflows. It’s important when the parts will be painted, coated, or assembled into precision devices.

Advantages	Disadvantages
Improves safety and handling	Adds to lead time if done manually
Enhances surface finish and appearance	May slightly alter edges if not carefully controlled
Prepares parts for coating or painting	Requires longer setup and programming time

 

When to Use Deburring

Deburring should always follow CNC machining or laser/plasma cutting. Especially when precision or safety matters. If your part is going to be assembled with others, or if it’s visible to customers, removing burrs is essential for proper fit, finish, and handling.

Frequently Asked Questions (FAQ)

What Are the Most Common Sheet Metal Fabrication Techniques?

Folding, CNC machining, deburring, cutting, and forming are the most widely used. However, many parts involve 2-3 techniques in combination. Stamping is one of the most widely used forming methods for medium to high-volume metal parts. You can review our list of the top metal stamping companies in China for 2026 to see which factories specialize in deep draw, fine blanking and progressive die work.

What Is the Difference Between Folding and Forming?

Folding is a type of forming that creates straight-line bends. Forming is a broader term that includes bending, stamping, and rolling.

What Is the Full Sheet Metal Fabrication Process?

It typically follows this order:

1. Design
2. Cutting
3. Forming (e.g., folding)
4. Machining
5. Deburring
6. Assembly
7. Surface finishing

Conclusion: The Most Popular Sheet Metal Fabrication Techniques (And When to Use Each)

Not all sheet metal fabrication techniques offer the same value and knowing when to apply each one can make or break your project. Whether you need the fast, cost-effective bends that folding provides, the tight tolerances achieved through CNC machining, or the clean edges and safety of deburring, the right choice depends on your part’s design, function, and production scale.

This guide helped you understand where each method fits and how to think more strategically about sheet metal manufacturing.

At Haizol, we help you put that strategy into action. Our platform connects you with verified metal fabrication workshops across Asia. Submit one RFQ, compare multiple quotes, and partner with the supplier that best fits your project needs.