Sheet metal is an essential component in countless commercial HVAC systems, and the process of transforming flat metal into custom-designed parts is both intricate and highly skilled. We specialize in precision metal fabrication in Naperville, helping businesses and contractors get the high-performance ductwork, enclosures, and fittings they need for their systems to run efficiently.
Whether you’re new to the topic or just curious about how custom sheet metal work comes together, this overview will walk you through the key steps involved in sheet metal fabrication.
What Is Sheet Metal Fabrication?
Sheet metal fabrication is the process of cutting, shaping, and assembling flat sheets of metal into specific products or components. In commercial HVAC this often includes ductwork, vent hoods, custom plenums, and equipment enclosures.
Unlike pre-fabricated parts, custom-fabricated metal pieces are made to fit the exact specifications of your building and HVAC design—ensuring better performance and efficiency. We provide in-house metal fabrication, which allows us to maintain strict quality control, offer faster turnaround times, and tailor every job to your project’s unique needs.
Step 1: Design and Engineering
Every successful fabrication project begins with a plan. Our team works closely with contractors, engineers, or clients to understand the system’s requirements and create detailed design blueprints. This may include CAD (computer-aided design) drawings that outline dimensions, airflow demands, materials, and tolerances.
This phase ensures that every component will not only fit the space but also meet performance expectations. It’s the foundation of precise fabrication.
Step 2: Selecting the Right Materials
Depending on the application, we select sheet metal materials that best match the project’s needs. In HVAC systems, common materials include galvanized steel, aluminum, and stainless steel—each offering different strengths in terms of corrosion resistance, weight, and durability.
The right material choice plays a major role in how long your system lasts and how well it operates.
Step 3: Cutting the Sheet Metal
Once the design is finalized and materials are selected, the sheet metal is cut to size. At Althoff Industries, we use advanced cutting methods such as:
- Laser cutting for high-precision shapes
- Plasma cutting for thicker materials
- Shearing for straight-line cuts
Each method allows for clean, accurate cuts, minimizing waste and ensuring components fit together seamlessly.
Step 4: Forming and Shaping
After the sheets are cut, they need to be bent or formed into the required shapes. This is done using specialized equipment such as press brakes and roll formers. These machines apply force in controlled ways to create angles, curves, and flanges without compromising the metal’s integrity.
For example, forming a duct elbow or a custom transition piece requires precise bends and measurements to ensure proper airflow.
Step 5: Assembling and Welding
Once all parts are cut and formed, the next step is assembling the components. This might involve:
- Welding for permanent, airtight joints
- Riveting or bolting for removable or adjustable connections
- Seaming and sealing for HVAC ductwork to prevent leaks
This is where everything comes together into a finished product, ready to be installed on-site.
Step 6: Finishing and Quality Control
Before anything leaves our facility, we inspect every fabricated piece to ensure it meets the design specifications and quality standards. Depending on the application, we may also apply coatings or treatments to enhance durability or corrosion resistance.
Because we handle metal fabrication in Naperville in-house, our team ensures fast, accurate fabrication with fewer delays and better communication from start to finish. When you need precision-crafted sheet metal components for your commercial HVAC system, trust the experts at Althoff Industries.
We’ve been providing custom metal fabrication for decades, delivering high-quality work on time, every time. Our in-house fabrication shop allows us to control the process, maintain strict quality standards, and meet the unique demands of any project.
Contact Althoff Industries, Inc. Challenges Accepted! We’re to help with your sheet metal fabrication and other commercial needs.