Sheet Metal FAQ

Sheet Metal Fabrication is a subtractive manufacturing process where we cut, bend, and assemble metal sheets into functional parts. At Boona Prototypes, we combine high-speed Fiber Laser Cutting with precision CNC Bending to produce durable enclosures, brackets, and chassis. It is the most cost-effective method for creating large, thin-walled metal parts compared to CNC Machining.

We can handle sheet sizes up to 3000mm x 1500mm (approx. 10ft x 5ft). This allows us to fabricate large-scale equipment covers, architectural panels, and server racks in a single piece.

Unlike machined parts, sheet metal has different tolerance standards (ISO 2768-m): • Laser Cutting: ±0.1mm. • Bending (Forming): ±0.3mm to ±0.5mm (depending on the number of bends). • Welded Assembly: ±1.0mm. For critical features (like bearing holes), we recommend post-machining to achieve tighter precision. Learn more about our Quality Control.

No. Boona Prototypes is specialized in Low-Volume Manufacturing. Whether you need a single prototype for fit-check or 500 units for a pilot run, we are happy to support you.

 Yes. For flat parts (laser cut only), we can ship within 24 hours. For bent and powder-coated parts, our standard lead time is 3-5 days. Check our Rapid Prototyping Services for urgent needs.

The price is primarily driven by three factors:

1. Material Utilization: How many parts can fit on a standard sheet (nesting efficiency).

2. Laser Path Length: Longer cutting time equals higher cost.

3. Number of Bends: Each bend requires manual setup and handling. Tip: To reduce costs, use standard gauges and avoid complex internal contours. Get an instant estimate via our Online Quote Form.

Yes, significantly. For parts with uniform wall thickness (like boxes, covers, clips), Sheet Metal is 50-80% cheaper than CNC machining because there is less material waste and faster processing time.

The setup fee covers the time required to program the laser cutter and configure the CNC brake press tooling. However, at Boona, we wave the setup fee for orders over 50 units.

Please upload your 3D STEP/IGES files (for bending calculation) and 2D PDF drawings (specifying threads, tolerances, and finish) to our Online Quote Form. We usually quote within 24 hours.

The K-Factor is the ratio representing the location of the neutral axis during bending. You do NOT need to calculate it. Just send us the 3D model. Our engineers will apply Boona’s specific tooling K-Factor to unfold your design accurately, ensuring the final dimensions match your drawing.

To prevent cracking, we recommend an internal radius equal to the material thickness (1T): • Aluminum: 1T (e.g., 2mm sheet = 2mm radius). • Steel: 1T. • Stainless Steel: 1.5T (harder material requires a larger radius).

 A hole should be placed at least 2.5x Material Thickness away from the bend line. If a hole is too close, it will distort into an oval shape during forming. Solution: If you need a hole closer, we can drill it after bending (secondary operation).

Bend reliefs are small notches cut into the side of a flange. They prevent the metal from tearing at the corners during bending. We recommend a relief width of at least the material thickness.

Yes. We can form Open Hems, Closed Hems, and Teardrop Hems. Hems are excellent for creating a safe, rounded edge on exposed parts (preventing cuts) and increasing stiffness.

• Aluminum: Up to 12mm. • Stainless Steel: Up to 10mm. • Carbon Steel: Up to 20mm. For thicker plates, we may use Waterjet or CNC Milling.

Choose 5052. Aluminum 5052-H32 is the standard for sheet metal because it bends without cracking. Avoid 6061-T6: It is brittle and often cracks at the bend line unless it is annealed (softened) first. See our full Material List.

• SPCC (Cold Rolled Steel): Requires plating or painting to prevent rust. Cheap and strong. • SECC (Galvanized Steel): Has a zinc coating that prevents rust. Ideal for internal chassis parts that don’t need painting.

Yes. We fabricate Copper (C1100) for busbars and electrical contacts, and Brass (H59/C260) for decorative panels. Note that these are highly reflective and require special laser settings.

• 304: The industry standard. Good corrosion resistance. • 316: Medical/Marine grade. Contains Molybdenum for superior resistance to salt water and chemicals. Recommended for outdoor enclosures.

Yes. We use automated hydraulic presses to install PEM nuts, studs, and standoffs. This provides strong, reusable threads in thin sheets, which is essential for mounting PCBs and components.

We offer: • TIG Welding: For aluminum and stainless steel (high aesthetics). • MIG Welding: For structural steel brackets (high strength). • Spot Welding: For joining overlapping sheets quickly. We also grind down welds to create a seamless “invisible” joint before painting.

Yes. We can CNC countersink holes to allow flat-head screws to sit flush with the surface, providing a smooth finish.

Absolutely. As part of our One-Stop Service Solution, we can rivet, bolt, and assemble hinges, handles, and locks onto your sheet metal enclosure, delivering a ready-to-use product.

• Powder Coating: The industry standard for metal. It is harder, more durable, and eco-friendly. Available in any RAL color and textures (sand/matte/gloss). • Wet Painting: Used when specific color matching (Pantone) is critical or for non-metal parts. Check our Surface Finishing Options.

Anodizing creates a hard, protective oxide layer. It is only for Aluminum. It provides a premium, metallic look (Clear, Black, Blue, Red). Note: Welded areas will show color differences after anodizing.

Alodine (Chem Film) is a conductive coating for Aluminum. It provides corrosion resistance while maintaining electrical conductivity (grounding). Ideal for electronic chassis.

Yes. We can laser engrave part numbers, logos, and QR codes. For multi-color logos, we use Silk Screening (Pad Printing).

Brushed finish (Hairline) is a mechanical texture applied to Stainless Steel or Aluminum. It hides fingerprints and scratches, commonly used on kitchen appliances and front panels.

We use 2D Optical Scanners to verify flat patterns and Digital Calipers/Protractors to check bend angles. For complex assemblies, we use CMM inspection.

Yes. We respect your intellectual property. We are happy to sign a Non-Disclosure Agreement (NDA) before you upload any files.

Yes. We provide material certifications and inspection reports upon request to ensure the steel/aluminum grade meets your specifications.

 Large flat sheets with many holes can warp due to heat release. Solution: We use “skip cutting” techniques to distribute heat or recommend CNC Machining for flatness-critical parts.

Boona Prototypes stands behind our quality. If parts do not meet the drawing specifications, we will rework them or reproduce them free of charge.

Yes. Our DFM (Design for Manufacturing) engineers can help convert your solid block design into an unfoldable sheet metal design to save costs.

• Choose 3D Printing: For complex organic shapes, tiny prototypes, or plastic parts. • Choose Sheet Metal: For large enclosures, structural brackets, EMI shielding, and heat resistance.