Sheet metal assembly involves joining multiple metal parts to create a finished product or components. Whether you’re building a rugged piece of industrial equipment or assembling a compact enclosure for electronic systems, the method of assembly plays a role in durability, cost, and lead time.
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At EZG Manufacturing, we work with businesses that need more than just parts; they need fully assembled solutions. Backed by decades of experience and equipped with advanced fabrication tools, we provide everything from precision cutting to finished assemblies.
Below, we break down the most common sheet metal assembly techniques, how they’re used, and where they provide the most value.
Sheet metal assembly is the process of taking cut and formed metal components and fastening them together using various techniques. These parts can range from flat patterns to fully shaped brackets, panels, or structural elements. The goal is to turn individual sheet metal components into a reliable final product.
Different projects require different techniques depending on the material (such as carbon steel or stainless steel), the assembly environment (from aircraft assembly facilities to construction sites), and functional needs like weight, part count, or corrosion resistance.
Welding is one of the most reliable ways to assemble metal components. At EZG, we use both MIG and TIG welding to join parts depending on the thickness, material, and desired finish.
Welding works by applying intense heat to melt the edges of the metal pieces, fusing them together as they cool and solidify. Each method creates a strong bond, often stronger than the base metal itself.
Our team includes AWS-certified welders and robotic welding systems for consistent results on both small and large batch orders.
Mechanical fastening is often the preferred solution when:
This method involves drilling or punching holes into parts and inserting hardware such as rivets, bolts, or sheet metal screws. These fasteners can create either permanent or removable joints, depending on the application.
At EZG, our technicians use assembly riveters, hand tools, and precision drilling to prepare threaded holes and mounting points, giving clients the flexibility they need in both prototyping and full production.
Adhesive bonding is a great option when welding or fasteners could interfere with aesthetics, introduce distortion, or aren’t compatible with certain materials. It’s commonly used to join:
This method involves applying industrial adhesive or epoxy between surfaces, which is then cured using time, heat, or pressure to form a durable bond. Adhesives also distribute stress more evenly across the bonded area, making them well-suited for lightweight or vibration-prone designs.
While not the solution for every project, adhesive bonding is ideal for custom applications that demand flexibility or uniform stress distribution.
Hemming is the process of folding the edge of a sheet metal part over itself to create a rounded, reinforced edge. This not only improves strength and safety but also offers a cleaner appearance than raw edges.
Using a press brake or hemming tool, we perform:
This technique is frequently used in:
Hemming helps reduce sharp edges, increase stiffness, improve multi-panel alignment, and even reduce part count, making it a cost-effective way to prep components for final assembly.
This technique uses precisely cut tabs and slots to lock parts together before final fastening. It’s often paired with welding or bonding and is:
Tabs fit tightly into slots, holding components together during final assembly and reducing the need for clamps or jigs. This self-fixturing approach is especially helpful in projects requiring high repeatability or tight tolerances.
Thanks to EZG’s in-house laser cutting capabilities, we frequently use this method to speed up assembly time, particularly for high-volume or repeat builds.
Clinching mechanically interlocks two layers of sheet metal without any added hardware or heat. Using a punch and die, it forms a dimple that locks the metals together.
Benefits include:
Clinching is often used in:
This technique is ideal when speed, cleanliness, and cost-efficiency are key concerns.
When your project needs components that mount circuit boards, covers, or brackets, stud and PEM fasteners provide reliable threaded attachment points.
We insert PEM studs, standoffs, and nuts directly into metal sheet parts before final assembly.
These are used in:
Our CNC presses support high-speed insertion and consistent placement across parts, helping you maintain tolerances and fit.
Modern designs often combine sheet metal parts with electronics, wiring, or plastic elements. EZG’s team supports complete electromechanical assembly, including:
The process includes mounting PCBs, connecting wires to terminals, and installing hardware, all within metal enclosures fabricated in-house. This eliminates the need to coordinate with separate vendors for mechanical and electrical integration.
This is a common need in fields like medical, construction technology, and industrial automation, where a single source for both fabrication and assembly reduces complexity.
Assembly isn’t complete until your parts are finished and ready for use. At EZG, we offer in-house powder coating and wet paint booths to meet your appearance, durability, or spec requirements.
Powder coating involves spraying electrostatically charged powder onto metal surfaces, which is then cured in an oven to form a tough, uniform finish. It protects against corrosion and wear, and allows for consistent color and texture across production runs. Our finishing services help maintain the look and function of your sheet metal products from the inside out.
Benefits of in-house finishing services:
This full-service model saves time and helps maintain quality throughout the entire production cycle.
Choosing the best assembly method depends on:
At EZG, our engineers assist with design reviews and can adapt sheet metal designs to suit faster production or easier assembly.
EZG Manufacturing isn’t just a fabrication shop, we’re a complete production partner. With over 120,000 sq. ft. of manufacturing space, heavy lifting capabilities, and advanced tools like our 10k fiber laser and 350-ton brake press, we’re built for projects ranging from a single metal part to full complex assemblies. We handle everything from laser cutting and welding to finishing and custom property creation.
From flat pattern to final product, our goal is to give you one point of contact and a finished product that’s ready for use.
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This is a great project to make if you are new to working with sheet metal. At this point in my class all of our sheet metal projects have been very simple with, at most, one bend. But, when we get to the this project my students always have a hard time trying to think through how to construct something from one piece of flat material. They begin to understand a little better when I relate what we are doing to an unfolded cereal box but until they work through making this box it usually doesn't make sense to them. This project makes them stretch their problem solving muscles by making them think through the correct order of operations to end up with a quality little container.
My students start off not liking this project as it really steps up the level of difficulty from our previous two projects but they end feeling very accomplished and finally coming to the conclusion the project wasn't really that hard to begin with. Plus, they like that they've finally made something that they can use and take home.
In this Instructable I'm going to walk you through how to make one of these simple sheet metal boxes!
If you are just beginning to work with sheet metal I recommend also checking out my two previous sheet metal Instructables. They cover how to make SHEET METAL DOG TAGS and SHEET METAL VISE JAW COVERS.
If you prefer watching over reading the video above covers the step by step instructions for this fabrication project in under eight minutes.
Tools and Equipment
Materials
Before we begin we need a plan of action. If you can't visualize how the flat pattern for a box should look with sheet metal, find an old shoe box or cereal box and unfold it. The patterns for a cardboard box will look very similar to what you need to plan out for the sheet metal box.
The box I have my students create in class ends up being 5.5" x 2" x 3.5". To make things easy for my students I designed our classroom box so it would be able to work on the size of a standard 8.5" x 11" piece of paper. This size allows my students to practice their layout pattern and folding on paper before they move to metal. If your plan works on a paper mock up it should work on sheet metal.
I've included a picture and a pdf file of the plans I use in my class. Feel free to use it exactly as dimensioned or just use it as a template for your own size of box.
Terms to know:
There are are couple of terms that you'll want to know to help you understand the plans if you haven't worked with sheet metal before.
Hem - A section of your metal that has been rolled over onto itself. The hems will be located on the top edges of your box to provide a nice smooth rounded edge instead of a sharp, jagged one.
Tab - An additional piece or strip of metal that will be used in assembling or holding the sheet metal to the desired form.
Making a mock up out of cheap material is always a good practice to have when building something you are unfamiliar with doing. I have my students create their box out of paper first before I allow them to move on to working with the sheet metal. The process I show my students for laying out their pattern on paper is the exact same process they will use when they move on to the real deal. When you are finished with your mock up and it is the same size as what you planned; your work with sheet metal should go pretty smooth. If your mock up comes out with uneven sides, the corners don't connect, or its too small/large, then it will probably be a good idea to go back to the planning phase and make some revisions to your idea.
The order of operations for this step are as follows:
Once you are prepared to work with your metal the first step you will need to take is to get your stock piece to the needed size. Using your plans measure and mark your overall size measurements on your metal. It is important to mark your lines nice and straight, a square will help you with that. If you do end up marking your lines slightly at and angle you will have a much harder time having your box come out as you planned.
For this step I used a foot shear to cut my metal to size. A foot shear made this step quick and easy and left me with nice clean edges on my metal. If you do use a foot shear be sure you line up your marked lines in the correct spot on your shear before cutting. I have included a picture showing how my marked line is right off the edge of the table of my shear, which will give me the exact measurement I want on my cut. A foot shear isn't necessary, as you could also do this step with hand snips.
The order of operations for this step are as follows:
Now that your metal is to the correct size, it is time to mark your layout pattern onto the metal. I recommend using a square for this step if you have one, it will ensure you get as straight as marked lines as possible. Overall this is the same process as making the mock up, if you decided to complete that step. Just take your time and make sure the lines you are marking are correct and the way you want them to be. Below I've included the order of operations I have my students use.
The order of operations for this step are as follows:
With your layout marked it is time to use aviation snips to cut your metal to shape. Overall this step is pretty easy, but using snips on metal can be a real grip strength workout. The biggest mistake my students make is going to fast and they end up cutting off one of their tabs. Take your time and make sure you are cutting the areas that are supposed to be cut.
The order of operations for this step are as follows:
When you spot weld the box together you want as clean of connection between the metal as possible. That means before you start doing any bending you will want to clean up the portions of your metal where the spot welds will be located. It will be much easier to clean up your tabs and sides of your box now before you bend. To do this you will want to sand off the layout fluid and any oil and grease on the metal. This will allow you to have a clean metal to metal connection when we spot weld which will give us the strongest connection possible.
To do this just get some emery cloth or some 80 grit sand paper and clean off the inside and outside of your metal wherever your tabs will overlap your sides.
As stated earlier hems are just a section of your metal that has been rolled over onto itself. The hems will be located on the top edges of your box to provide a nice smooth rounded edge instead of a sharp, jagged one. To do this step I will be using a bar folder but the process can be done with a sheet metal brake as well. Your goal with your hems is to have your doubled up layer of metal be flat without any bubbles or dents. The key to getting your hems correct is to use a tapping, not a heavy hammering, motion while also keeping your hammer head flat against your metal. If you use too much force or have your hammer head slightly angled you will end up with dents across your hems. Just like all the steps of any project you do, take your time and pay attention.
The order of operations for this step are as follows:
You are almost done. Once the hems have been made the next step is to bend your metal into a box. You will be working with a sheet metal brake to complete this step. The goal here is to clamp your brake teeth right on your lines. If your line is clamped down at an angle to your brake teeth, you will bend your metal at an angle and your box will not come out as you hope. Also, you will need to move some teeth on your break or you will not be able to fold your metal correctly. Move the teeth on your break around until you have a setup where you can insert your shorter side underneath so your tabs won't be crumpled during bending.
The order of operations for this step are as follows:
You now have a box! But without some form of fastening/assembly the box can be unfolded or deform pretty easily. To keep it in the shape you want it we need to make some sort of connection between your tabs and the sides of your box. For this I am going to spot weld the tabs to the sides of the box. If you don't have a spot welder, mechanical fasteners would work fine as well. Something like pop rivets or machine screws is what I would recommend if you wanted to go that route. You already prepared your metal for this process in a previous step, so all that is left is to actually spot weld. Please be sure to wear all the required and proper PPE (Personal Protective Equipment) when using the spot welder. Our spot welder owners manual recommends safety glasses, a face shield, gloves, closed toed shoes, and long pants.
The order of operations for this step are as follows:
You now have a nice little container to use around the shop! If you feel the need for a lid, like I show in some of the pictures, just repeat the same process but make the box slightly bigger overall, but only design it to have about half the height.
For painting I used just regular spray paint that can be used on metal. Be sure to clean your metal up before painting by sanding it clean of oil and rust. Then be sure to wipe away any dust or metal shavings left behind after the clean up.
This Instructable I found to be more challenging to explain just through texts and pictures. If you need further explanation on a given step just leave me a questions in the comments below and I'll try to answer to the best of my ability.
If you make a box, let me know!
Enjoy creating and learning!
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