How to Go From 3D Modeling to a Quality Custom Metal Fabrication

When it comes to turning an initial part design into a custom metal fabricated piece, the journey isn't always smooth. This is where 3D modeling services come in handy, helping to bridge the gap between your CAD drawings and the final 2D plans needed for metal fabrication.

Working with a structural steel detailer who has fabrication experience is crucial. They can navigate tools like CAD, 3D modeling, and CAM (Computer-Aided Manufacturing) software to find the most efficient way to produce your part. This is particularly important in structural steel detailing, which involves several steps before the design can progress further.

Let's start by looking at the critical design phase and how it ties into the entire structural steel detailing process.

The Design Phase: Laying the Foundation for Fabrication

Your design is more than just an idea; it’s the blueprint for creating something tangible. Think of it as your first draft in the world of custom metal fabrication.

After creating your initial product design, a steel detailer can use 3D modeling to create detailed shop drawings for the fabricator. This is where adjustments can be made to optimize the part for production. Keep in mind that having a product design doesn’t automatically mean it can be manufactured as-is, especially for custom steel products. Often, the design goes through a "fabrication design" stage before moving forward.

This is why it’s essential to work with an experienced steel detailer like Southern Metal Fabricators, who can act as your engineering and design partner. They will analyze various factors to ensure that your final product:

• Can be successfully fabricated.
• Retains its strength, durability, and integrity.
• Can be assembled or arranged as intended.

Shaping Metal: Turning Designs into Reality

Your structural steel detailing partner needs to excel at bending, shaping, punching, and forming metal to meet most custom metal fabrication demands. Custom metal forming involves shaping raw stock into the desired forms using powerful industrial machines that can apply the necessary forces and pressures to achieve precise tolerances.

For instance, sheet metal rolling often uses specialized hot rolling to create raw metal stock. Cold rolling is typically used for shaping sheet or plate metal into cylinders or curves. Plate rolling creates curves, while angle rolling forms defined angles, usually at 90 degrees.

When it comes to metal bending, both mechanical and CNC hydraulic press brakes can bend metal plates up to 12 feet long to any angle. At Southern Metal Fabricators, we have four press brakes, including a massive 400-ton machine that can handle ¾-inch steel plates and a ten-tonner for more delicate projects.

For heavy-duty steel punching, our 50-ton hydraulic web and flange beam punches provide the power needed for mass production. However, when precision is key, we rely on our CNC 30-ton Strippit punch press for consistent and accurate results.

Cutting Metal: Precision Meets Functionality

Custom metal cutting services are vital for meeting your industrial specifications. The cutting process may involve specialized saws, shears, and high-definition plasma or laser cutters. Punching, a subset of cutting, creates holes or openings in metal pieces.

At Southern Metal Fabricators, we can cut metal to almost any size or shape, from delicate copper sheets to thick carbon-steel I-beams. Our metal cutting capabilities include metal sawing, CNC plasma cutting, steel plate shearing, and laser cutting services, thanks to our advanced equipment like the Trumpf laser cutter.

Finishing Touches: Ensuring Quality

A full-service custom metal finishing shop is essential for maintaining quality in metal fabrication. At Southern Metal Fabricators, our extensive onsite finishing services include surface preparation and final finishing. We understand that carbon steel can rust quickly if not treated properly, so we focus on immediate painting after surface preparation.

Our custom finishing services include:

• Surface preparation: We can prepare metal surfaces for grades SP1–SP10, including steel blasting for a superior finish while saving time and labor costs. Wire brushing or metal bead blasting techniques are also available.
• Hot-dip galvanizing: After constructing a structure or sub-assembly, we often apply hot-dip galvanizing. We can also fabricate with galvanized material, commonly used for outdoor industrial ladders and stairs.
• Metal fabrication painting: Once the surface is prepared, applying primer and paint in a controlled environment ensures a quality finish. Each layer is carefully measured for thickness, and we document the process if strict tolerances are required. Direct-to-metal (DTM) paint, combining primer and finish paint, is also used to protect metal from the elements.

Welding: The Backbone of Quality Assemblies

In addition to structural steel detailing, Southern Metal Fabricators offers custom welding services to ensure every assembly and subassembly fits together seamlessly. Our certified welding professionals bring over 30 years of experience in all relevant codes and standards governing custom metal fabrication.

We are familiar with ASME and American Welding Society protocols, as well as Canadian welding standards (CWB). Our commitment to quality extends to providing supporting documentation throughout the process.

Our in-house welding equipment includes MIG gas metal arc welding machines, TIG welders, and stud welding machines. We are also qualified to weld structural steel according to AWS D1.1 (carbon steel above 1/8” gauge) and AWS D1.6 (stainless steel above 1/16” gauge) standards.

Choosing the Right Steel Detailer

As mentioned earlier, it’s important to work with a structural steel detailer who understands your specific industrial requirements. A good detailer should possess strong communication skills, familiarity with industry standards, and expertise in 3D modeling and design software.

When selecting a detailer, look for someone who:

• Communicates effectively with designers and fabricators to prevent issues if design changes are needed.
• Is knowledgeable about industry standards, especially if the fabricated product will be part of a construction project.
• Has expertise in CAD, 3D modeling, and CAM software to optimize parts for fabrication.

Structural Steel Detailing: Experience Matters

Structural steel detailing and custom metal fabrications form the backbone of modern infrastructure, from agricultural hoppers and silos to industrial ladders and water towers. Many manufacturers choose Southern Metal Fabricators as their detailing partner due to our extensive experience and investment in cutting-edge automation for materials processing.

In addition to 32 years of fabrication experience, we have equipped ourselves with industry-leading automation to serve as your off-site structural processing center.

Visit our structural steel fabrication page to learn more about the benefits of outsourcing your next detailing or processing project. Or contact us today to see how we can help with your custom metal fabrication needs.