What Is Metal Fabrication?
Metal fabrication is the process of transforming raw metal materials into finished products or components through a series of manufacturing techniques. It encompasses everything from cutting and shaping flat sheet metal into enclosures and brackets, to welding structural steel beams for large-scale construction projects. At its core, fabrication takes a design concept—whether a simple sketch or a detailed CAD drawing—and turns it into a tangible, functional piece of metalwork.
At Alliance Metal Solutions in Somersby, NSW, we work across the full spectrum of fabrication processes, handling projects from single prototypes through to high-volume production runs. Understanding each stage of the fabrication process helps our clients make better decisions about design, materials and manufacturing methods.
Common Metal Fabrication Processes
Cutting
Cutting is typically the first step in any fabrication project. The goal is to separate raw material into the required shapes and sizes with as much precision and efficiency as possible. Modern fabrication shops rely on several cutting technologies, each suited to different applications.
Laser cutting uses a focused beam of light to melt or vaporise material along a programmed path. It delivers exceptionally tight tolerances—often within ±0.1 mm—and produces clean edges that frequently require no secondary finishing. Laser cutting is ideal for thin to medium-thickness sheet metal in materials such as mild steel, stainless steel and aluminium. For projects requiring this level of precision, our metal laser cutting service uses state-of-the-art fibre laser technology.
Plasma cutting is better suited to thicker materials where speed is more important than ultra-fine edge quality. It uses an electrically charged gas to cut through conductive metals at high speed, making it a cost-effective choice for structural steel and heavy plate work.
Other cutting methods include shearing for straight-line cuts on sheet metal, waterjet cutting for heat-sensitive materials, and sawing for bar stock and structural sections.
Bending and Forming
Once material has been cut to shape, it often needs to be bent or formed into three-dimensional profiles. CNC press brake bending is the most common method, using a punch and die set controlled by computer numerical control to produce accurate, repeatable bends. Modern press brakes can handle complex multi-bend sequences with tight angular tolerances, making them essential for producing brackets, channels, enclosures and panels.
Our CNC bending service utilises multi-axis press brakes capable of handling material thicknesses from 0.5 mm up to 12 mm, with bend lengths up to 3 metres. Roll forming and tube bending are additional forming processes used for curved profiles and tubular components.
Welding and Joining
Welding is the process of fusing two or more metal components together using heat, pressure, or a combination of both. It is fundamental to nearly every fabrication project, whether assembling a simple frame or building a complex structural assembly.
The most common welding processes in fabrication include MIG (Metal Inert Gas) welding, which is fast and versatile; TIG (Tungsten Inert Gas) welding, which produces the highest quality welds on thinner and more demanding materials; and stick welding, which remains popular for heavy structural work and field repairs.
Skilled welders are critical to fabrication quality. At Alliance Metal Solutions, our welding team holds certifications to AS/NZS 1554 and works across mild steel, stainless steel and aluminium. Every welded assembly undergoes visual inspection, and we offer additional non-destructive testing when specified.
Finishing
The final stage of fabrication involves surface preparation and finishing. This may include grinding and deburring to remove sharp edges, sandblasting or chemical treatment to prepare surfaces for coating, and the application of protective or decorative finishes.
Powder coating is one of the most popular finishing methods for fabricated metal. It provides a durable, even coating that resists chipping, scratching and corrosion far better than conventional wet paint. Read more about the benefits of this process in our article on the advantages of powder coating.
Other finishing options include hot-dip galvanising for outdoor structural steel, anodising for aluminium components, and electroplating for decorative or specialised applications.
Material Selection
Choosing the right material is just as important as selecting the right fabrication process. The three most commonly fabricated metals are mild steel, stainless steel and aluminium, each offering distinct advantages depending on the application. Mild steel is the most affordable and widely available option, stainless steel provides excellent corrosion resistance for food-grade and marine environments, and aluminium offers the best strength-to-weight ratio for weight-sensitive applications.
For a deeper dive into material selection, see our guide on how to choose the right metal for your fabrication project.
Quality Standards in Metal Fabrication
Reputable fabrication companies work to recognised quality standards to ensure consistency and reliability. In Australia, key standards include AS/NZS 1554 for structural steel welding, AS 4100 for steel structures, and ISO 9001 for quality management systems. These standards govern everything from material traceability and welding procedures to dimensional tolerances and inspection requirements.
At Alliance Metal Solutions, quality control is integrated into every stage of our process. From incoming material inspection through to final dimensional checks, we ensure that every component leaving our Somersby facility meets the required specifications.
Partnering with the Right Fabricator
Whether you need a single prototype or ongoing production of thousands of parts, the success of your project depends on working with a fabricator who has the right equipment, experience and quality systems. Our team at Alliance Metal Solutions brings decades of combined experience in sheet metal fabrication, cutting, bending, welding and finishing—all under one roof.
If you have a fabrication project in mind, get in touch with our team for a no-obligation discussion and quote.