Everyone makes mistakes — even skilled professionals can run into fabrication errors. Mistakes can cost you significant money, time, and materials. However, many of them can be avoided with a bit of extra precision, planning, and the right tools.
In this blog post, we’ll highlight some frequent mistakes in the metal fabrication process, explore expert tips for avoiding these pitfalls, and how proper machinery and tools can reduce or eliminate many manufacturing issues.
Mistake #1: Inaccurate Measurements
You’ve probably heard the phrase, “Measure twice, cut once.” There’s a reason it’s so common — it’s true! Measurement errors can throw off entire fabrication projects, leading to misaligned parts, material waste, and failed quality checks.
To avoid this, use precision measuring tools, and double-check all measurements before cutting or welding. Consider digitizing the measurement process with CNC machines and CAD software.
Mistake #2: Ignoring Material Properties
When working with metal, it’s important to recognize that not all types of metal behave the same. Different materials require different manufacturing processes to prevent warping, cracking, reduced strength and durability, and compromised aesthetics.
If you’re considering working with a material you don’t have much previous experience with, take some time to understand the metal’s grain structure, hardness, and thermal behavior. Choose the right fabrication techniques and machinery to the material’s unique properties, and train your shop employees on the specifics of working with this metal.
Mistake #3: Skipping Equipment Maintenance
Equipment maintenance isn’t fun, but it’s an essential part of running a fabrication shop. Ill-maintained machinery is a recipe for imprecise work, unexpected breakdowns, and safety hazards.
Implementing a regular maintenance schedule is worth the time and effort. It’s an investment in the efficiency of your daily operations and the quality of your output. Train your staff to recognize signs of wear or malfunction. If your machinery is nearing the end of its lifespan, invest in high-quality replacements with good manufacturer support.
Mistake #4: Poor Welding Practices
Welding is a skill that takes a lot of time to master. Unfortunately, welding mistakes are common, jeopardizing the integrity of metal structures with weak joints, excessive spatter, corrosion, or distortion.
If you’re looking for ways to improve the quality of your shop’s welded products, ensure your welders are properly trained on using the right welding techniques and settings for each type of metal, and ensure they maintain proper cleanliness of surfaces.
Mistake #5: Neglecting Safety Protocols
There’s a saying that’s often tossed around in industrial settings: “Safety regulations are written in blood.” While it may sometimes be inconvenient to follow safety protocols, they exist for a reason. Rushing or skipping these important steps can result in injuries, accidents, project delays, and legal liabilities.
As the boss, it’s your job to provide proper PPE and enforce its usage, keep machinery up to code with safety guards and emergency stops, and conduct regular safety training and drills. You’ll be glad you did when you avoid disaster.
Mistake #6: Not Accounting for Tolerances
Tolerance is the allowable deviation from specified measurements. Depending on the project, the tolerance can range between a few hundredths to a few thousandths of an inch. When you assume a part has exact dimensions without factoring in tolerance, parts may not fit or function properly, causing assembly issues and performance failures.
You should always define and follow tolerance specifications in plans and drawings to account for miniscule deviations, and train your staff to do the same. If near-exact measurements are especially critical, use high-precision machinery to minimize inconsistencies.
How the Right Machinery Can Prevent These Mistakes
Investing in the right machinery is one of the most effective ways to prevent common metal fabrication mistakes and improve the quality of your products. Consider adding a CNC machine, press brake, shears, or other precision tools to your shop to reduce human error and switching to automated systems to ensure consistent results.
Choosing advanced equipment isn’t just about achieving higher speeds; it’s also about accuracy, efficiency, and long-term reliability. Plus, modern equipment often comes with built-in safety features and digital controls, facilitating ease of use.
Avoid Fabrication Mistakes with Sanson Machinery
At Sanson Machinery, we specialize in providing high-quality, precision fabrication machinery designed to reduce costly mistakes and improve results. Don’t hesitate to reach out to us for expert advice on selecting the best equipment for your shop or to receive a quote on any of our machinery.