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.

Band saws are an important tool for metal fabrication, allowing you to easily cut through raw materials and create a wide variety of products. This tool is essential for any metal fabricator’s shop; however, it can be difficult to know which type is best for your needs. 

Both horizontal and vertical band saws have strengths and weaknesses that make them suitable for different metalworking applications. At Sanson Machinery, we want you to be able to make informed decisions about which machinery suits your needs. That’s why we’re presenting this guide to band saws to help you determine the right tool for you. 

Understanding Horizontal Band Saws

There are two main types of band saws: horizontal and vertical. With horizontal band saws, the blade moves through the workpiece, typically cutting through larger stock. The mounted blade moves in a single direction, and the machine uses gravity or hydraulic feed for controlled cutting. They’re ideal for making straight, precise cuts on bars, pipes, and other heavy metal stock. 

Pros

Because horizontal band saws produce straight, precise cuts with minimal effort, they are ideal for high-volume cutting. They’re excellent for heavy-duty work, such as cutting thick metal stock and bundles. Additionally, they make your production process more automated, reducing operator fatigue. 

Cons

However, horizontal band saws come with some drawbacks, as well. They don’t provide much flexibility for irregular or angled cuts. Plus, they take up more space in a workshop, making them less suitable for smaller spaces. Automated models can also come with a higher initial investment. 

Exploring Vertical Band Saws

Vertical band saws feature a stationary blade in a fixed vertical position, allowing for manual control of the cutting direction. The machine’s operator moves the workpiece along the cutting path, creating intricate cuts, curves, and freehand designs. They’re common in sheet metal fabrication and detailed work. 

Pros

If you’re looking for a machine that can create intricate cuts, including angles and curves, a vertical band saw is your best bet. These machines give you more control, allowing for custom and detailed cuts. They can handle a variety of materials, including metal and composites. Furthermore, they require less floor space than horizontal saws. 

Cons

Vertical band saws require more manual operation than horizontal saws, increasing labor costs. Plus, they’re not ideal for repetitive, high-volume cutting tasks, and are less efficient for thick stock or straight cuts. 

Best Applications for Each Type

As you can see, both horizontal and vertical band saws come with distinct advantages, making them ideal for different projects. Here are some tips for choosing between the two options. 

When to Choose a Horizontal Band Saw

If your shop focuses on cutting heavy-duty metals like large bars, tubes, or structural materials, a horizontal saw is ideal. Their ability to create clean, consistent cuts with minimal manual effort makes them excellent for industrial metal fabrication and production environments. Additionally, if efficiency and automation are priorities for your shop, this machine is especially suited to your needs. 

When to Choose a Vertical Band Saw

Vertical band saws are great for detailed cutting, contouring, or irregular shapes. Its ability to create complex designs is unmatched. If you own a workshop that does prototyping, artistic metalworking, or repair jobs and need a versatile tool for different materials and custom projects, a vertical saw is the perfect tool for you. 

Factors to Consider Before Choosing

If you’re in need of a band saw for your metalworking shop, consider these factors to ensure you choose the right machine for your needs:

• Material type and thickness: Vertical saws are suited to thinner materials, while horizontal saws work better for thick stock. 
• Cutting needs: Determine whether you need the ability to create straight cuts or intricate patterns. 
• Production volume: Horizontal saws are the more efficient option for mass production scenarios. 
• Space availability: Since vertical saws take up less floor space, they’re better for smaller workshops. 
• Budget: Automated horizontal saws are typically more expensive than manual vertical saws. 

Reliable Metalworking Solutions from Sanson Machinery

At Sanson Machinery, we’re dedicated to providing high-quality machining solutions from the top manufacturers. Whether you know exactly what equipment you need or want to explore your options, we’re here to help you get what you need. Contact us today to receive a quote on any of our products.