Fabricated Assemblies Design Guide
We review part drawings, assembly interfaces, joining requirements, finish specifications and packaging needs to help coordinate the manufacturing process.
Get the Guide With Your QuoteCustom Sheet Metal Fabrication and Assemblies
BoValley supports custom sheet metal assemblies that combine cut, formed and joined components into functional structures. Depending on project requirements, an assembly may include brackets, panels, frames, enclosures, hardware and other mechanical elements.
Project Review
- Flat Pattern Review
- Sheet Grade and Thickness
- Finish and Edge Requirements
- Inspection Planning
- Assembly Scope
- Frames & enclosures
- Joining Review
- Fit & hardware access
- Stock Type
- Sheet and formed components
Overview
What Is a Fabricated Sheet Metal Assembly?
Fabricated assemblies combine sheet metal components through suitable methods such as welding, mechanical fastening, riveting and hardware installation.
Depending on the design, the manufacturing sequence may include cutting, deburring, bending, joining, surface finishing and final assembly.
BoValley reviews fit-up dimensions, joining locations, access for tools, visible surfaces and assembly tolerances to help reduce downstream integration issues.
Fabricated Assemblies Capabilities
A successful assembly depends on component fit, hole alignment, joining requirements, and dimensional control. We review these requirements against your drawings and agreed specifications to coordinate the appropriate fabrication and inspection steps.
Integrated Fabrication Processes
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
Flexible Joining Methods
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
Multiple Material Options
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
Custom Assembly Types
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
Dimensional Control & Fit
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
Finishing & Delivery Options
- Combine suitable cutting, forming, and joining processes for custom assemblies.
- Select materials and joining methods based on strength and design requirements.
- Review alignment, tolerances, and welding distortion to support assembly accuracy.
- Coordinate surface finishing, hardware, inspection, and delivery of components or complete assemblies.
MaterialsMaterials
Fabricated Assemblies Materials
Select sheet grades and hardware together. Joint geometry, corrosion exposure, and the finishing sequence can influence the choice.
- Aluminum Alloys
- Stainless Steel 304
- Stainless Steel 316
- Cold-Rolled Steel
- Galvanized Steel
- Carbon Steel
- Joint and filler compatibility
- Weld distortion
- Hardware and access
- Coating after assembly
- Sheet grade and temper
- Corrosion exposure
- Surface appearance
- Formability
- Galvanic compatibility
- Part stiffness
- Visible face protection
- Coating adhesion
- Deburring
- Edge condition
- Hardware compatibility
- Fastener material
- Weldability
- Finish thickness
Surface Finish Options
Plan the finish around the order of assembly. Decide which surfaces remain visible, which contact faces need masking and whether hardware goes in before or after coating.
| Finish | Description |
|---|---|
| Joint cleanup | Specify how visible welds, sharp edges and joined seams should be dressed. |
| Coated assembly | Plan coating access and protect threads, locating surfaces and other areas that need masking. |
| Finished components | Specify appearance at joints and decide which parts should be finished before hardware or assembly. |
The Process
How Are Sheet Metal Assemblies Made?
Review the assembly model, component drawings, bill of materials and joint details. Cut and form the parts, then check the fit and use a suitable fixture to locate them for joining. Install hardware and apply the agreed finish in the planned sequence. Inspect the assembled interfaces as well as the individual parts.
The advantages
- Integrated Components:• Combine multiple sheet metal parts into a functional structure.
- Joining Options:• Evaluate welding and mechanical fastening according to design needs.
- Assembly Fit Review:• Consider mating interfaces, clearances and installation access.
The challenges
- Finish Coordination:• Plan finishing around welds, fasteners and visible surfaces.
- Hardware Integration:• Coordinate suitable fasteners and assembly components where specified
QualityApplications for Fabricated Assemblies
Use fabricated assemblies for equipment that needs multiple panels, supports or frames to fit together. Specify interfaces and inspection dimensions on the assembly drawing.
Equipment Enclosures
Covers, panels, doors, and internal mounting structures.
Machine Frames & Supports
Fabricated brackets, supports, and frame components.
Industrial Cabinets
Multi-part sheet metal cabinets and housings.
Custom Product Structures
Integrated metal components designed for specific products.
Telecommunications Equipment
Assemble equipment housings, rack panels, and mounting structures.
Laboratory & Test Equipment
Combine access panels, instrument supports, and custom mounting hardware.
| Types of Parts | Function |
|---|---|
| Equipment enclosures | Integrate panels, mounting points, and access doors. |
| Machine frames | Join formed or cut components into aligned support structures. |
| Test fixtures | Combine brackets and panels with specified mounting hardware. |
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