Aluminum is widely used in custom sheet metal fabrication due to its appealing strength-to-weight ratio, corrosion resistance, and ease of forming. For procurement professionals sourcing custom aluminum sheet metal products and components, understanding how material selection, fabrication methods, and finishing requirements affect pricing and performance can streamline supplier communication and reduce costly revisions. Whether you’re working on decorative panels, structural brackets, or industrial fabrications such as ductwork, chutes, and air-handling components, the specifications you provide up front shape cost, lead time, and manufacturability.
Material Selection for Aluminum Sheet Metal Products
While aluminum is chosen because of its characteristics, it is important to understand that not all aluminum behaves the same way. The performance of aluminum components depends heavily on alloy and temper selection. Alloy affects corrosion resistance, strength, and weldability, while temper—how aluminum has been heat-treated or strain-hardened at the mill—impacts formability and structural integrity.
Two common alloys – tempers used in fabrication include:
- 5052-H32 offers excellent formability and corrosion resistance, ideal for enclosures, panels, ductwork, chutes, and architectural applications. The partially annealed H32 temper allows tight bends without cracking, making it suitable even for heavier-gauge forming.
- 6061-T6 provides higher strength but lower formability, requiring larger bend radii or careful design considerations for structural brackets and welded assemblies.
Clearly specifying both alloy and temper helps procurement teams avoid material substitutions or fabrication miscommunications. Engineers should incorporate these considerations early in the design process to align structural and performance expectations with material characteristics.
Aluminum sheet is available in numerous gauges, though not every alloy or temper combination is stocked consistently. For heavy-gauge forming and industrial applications typical of custom fabrication, thicknesses commonly range from .125” (1/8″) up to .375” (3/8″) or thicker. Less common alloys or specialized tempers can extend lead times, which procurement professionals should consider in their project planning.
Design Considerations to Contain Costs
Aluminum is easier to form than steel in many respects, but design features still impact tooling, setup time, and fabrication feasibility. Overly tight tolerances, non-standard bend radii, and highly complex geometries can lead to higher costs or delays.
Laser cutting is particularly effective for intricate shapes and precision tolerances, commonly used in applications like complex ductwork or architectural details. However, laser cutting aluminum sheets thicker than 3/8″ can become challenging, potentially requiring alternate fabrication processes. Designing with an understanding of these capabilities ensures smooth production processes and avoids costly rework.
Fabricators typically work from flat pattern files and 3D models. Early design reviews can identify cost-saving adjustments, such as simplifying formed features, adjusting joint styles, or aligning hole locations to reduce rework. Procurement professionals can speed up quoting by ensuring drawings include complete dimensions, tolerances, and finish specifications.
Finish and Post-Processing Requirements
If your part requires anodizing, powder coating, or polishing, it’s important to call that out in the initial specifications. Aluminum alloys and tempers respond differently to finishes; for example, 5052 generally provides a more uniform anodized finish compared to 6061. If aesthetic uniformity or corrosion resistance is critical, specifying the finishing process and expectations upfront can prevent later production delays or quality issues.
Surface finish requirements also affect both material prep and tolerances. A powder-coated part might require masking of joining surfaces or tapped holes. Parts that require post-coating modification will incur additional time and costs. Clearly identifying masking areas or threaded holes at the specification stage also reduces additional processing costs. Clear, early communication about finish standards—color, gloss, or corrosion performance—helps ensure the coating process aligns with expectations.
Because both alloy and temper affect mechanical properties, material certification must include both. If traceability or compliance is required, it should be stated at the time of RFQ. Some materials—especially those in specific tempers—must be ordered with certs from the supplier, and retroactive documentation may not be possible.
Collaboration Matters for Aluminum Sheet Metal Products
The most successful aluminum sheet metal products begin with clear, complete specifications and open communication with the fabricator. Procurement professionals can streamline the quoting and production process by understanding the technical aspects that influence cost and manufacturability. Engineers, meanwhile, benefit from involving fabricators during the design phase to ensure that parts can be made efficiently without sacrificing performance or quality.
Custom aluminum sheet metal products aren’t off-the-shelf solutions—they’re the result of smart decisions made upstream. With the right approach, you’ll get the part you need, at the quality level you expect, within your project timeline.
Choose S&R Sheet Metal for Your Next Project
Precision and expertise are crucial in aluminum fabrication. At S&R Sheet Metal, we provide custom solutions tailored to your specifications. Our team ensures every project meets high standards of quality and performance.
We manage each step with attention to detail. Our early design reviews help identify cost-saving adjustments and streamline production to keep your project on track and within budget. Whether you need complex ductwork or architectural details, our advanced capabilities ensure smooth production processes and avoid costly rework. Choose S&R Sheet Metal to benefit from our industry expertise and innovative solutions. Trust us to be your reliable partner in aluminum sheet metal fabrication. Contact us for a quote.