What is aluminum sheet metal fabrication?
Aluminum sheet metal fabrication produces parts by cutting, bending, welding and finishing aluminum sheet. At about a third of the weight of steel, aluminum is ideal for electronics enclosures, vehicle and caravan parts, panels, covers and lightweight brackets.
See Sheet metal fabrication for the general process and Aluminum for material properties.
Aluminum alloys for sheet metal
| Alloy | Bendability | Welding | Typical use |
|---|---|---|---|
| 1050 | Very good | Good | Simple covers, decorative parts |
| 3003 / 3105 | Very good | Good | Containers, roofing and facade parts |
| 5754 | Good | Very good | Enclosures, vehicles, general fabrication |
| 5083 | Good | Very good | Marine, tanks, heavy duty |
| 5005 | Good | Good | Parts to be decoratively anodized |
| 6082-T6 / 6061-T6 | Limited (needs large radius) | Good | Rigid brackets, structural parts |
5754 is the most popular alloy in sheet metal fabrication: it bends well, welds well and resists corrosion.
Bending guidelines
- The inside bend radius of aluminum depends on alloy and temper. Soft alloys such as 1050, 3003 and 5754 can be bent with a radius of about 1–1.5 × sheet thickness.
- T6-tempered 6061/6082 is hard and less ductile; it usually needs a radius of 2–3 × thickness or more to avoid cracking at the bend.
- Where possible, keep bend lines perpendicular to the rolling direction to reduce cracking risk.
- Keep holes at least 2–3 sheet thicknesses away from bend lines.
For details, see Sheet Metal Bending Design Guidelines.
Welding and joining
| Method | Description |
|---|---|
| TIG welding | Clean, precise welds on thin sheet |
| MIG welding | Fast joining on thicker sheet |
| PEM nuts and studs | Permanent threaded fasteners of a type suitable for aluminum |
| Rivets | Joining without heat |
Welding aluminum requires more experience than steel. 5xxx series alloys are the most suitable for welding.
Surface finishes
| Finish | What it provides | Note |
|---|---|---|
| Anodizing | Corrosion protection and colour | 5005 is preferred for decorative anodizing |
| Powder coating | Durable coloured coating | Specify a RAL code |
| Brushing | Decorative grained look | Mark the grain direction |
| Chromate conversion coating | Conductive corrosion protection | Electronics enclosures |
What drives the price
- Alloy and thickness.
- Cut length, number of bends and amount of welding.
- Finish (anodizing colour, powder coating).
- Hardware and quantity.
What we need for a quote
- STEP model of the bent part or DXF flat pattern with bending drawing
- Alloy and thickness (e.g. 5754 H22, 2 mm)
- Quantity and finish
- Hardware and welding details
Frequently asked questions
Which alloy should I choose for aluminum sheet metal?
For most enclosures and general fabrication, 5754 is the best balance. Choose 1050 or 3003 for simple, easily bent parts and 5083 for marine environments.
Can 6061-T6 aluminum sheet be bent?
It can, but because it is hard it may crack at the bend. It needs a larger bend radius; where bending is required, choose a softer alloy such as 5754 if possible.
Can aluminum sheet be anodized?
Yes. For a decorative, uniform anodized look, 5005 is preferred; other alloys may show colour variation.
Can aluminum sheet be welded?
Yes, by TIG or MIG. 5xxx series alloys are the most suitable for welding.