Material removal
In which the sheet metal is cut in various ways

ZigiTech provides engineering-driven sheet metal fabrication for product teams that need precision, responsive lead times, and scalable manufacturing support from early validation to stable production.


Because thin metal sheets are more malleable than thick stock, our manufacturing service applies process-specific tooling to form accurate geometry and stable repeatability.
These processes fall into three general categories:
In which the sheet metal is cut in various ways
In which the sheet metal is bent or formed
In which the sheet metal is joined to other components
At ZigiTech, our manufacturing service combines laser cutting, bending, stamping, deep drawing, and welding to keep complex sheet metal programs accurate from first build to repeat production.
From one-off prototypes to high-volume batches, we support flexible order planning so your team can validate quickly, then scale with the same process discipline and factory controls.
Our engineering-led workflow shortens handoff time and production setup, helping product teams hit launch milestones without sacrificing dimensional consistency or surface quality.
As a trusted Metal Processing Company, we process aluminum, steel, stainless steel, and copper with documented quality checks to meet drawing intent and inspection requirements.

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In our Manufacturing Service workflow, laser cutting uses a focused beam around 0.001 in (0.025 mm) in diameter to deliver clean edges and tight profile accuracy.
With focal lengths between 1.5 in and 3 in (38-76 mm), this process can hold tolerances near +/-0.002 in (+/-0.05 mm) and kerf widths around 0.006-0.015 in (0.15-0.38 mm), making it suitable for detailed geometry.
Advantages: High precision, minimal finishing, and broad material compatibility.
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Water jet cutting applies a high-pressure stream, with abrasive when needed, to process thicker materials while preserving edge integrity.
Because it is a cold-cutting method with no heat-affected zone, it is well suited for alloys sensitive to thermal distortion and for parts that require stable material properties after cutting.
Advantages: No thermal damage, high precision, and strong material flexibility.
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Plasma cutting uses a high-temperature ionized arc to remove material rapidly and cost-effectively, especially on thicker sheet and plate applications.
This method supports high throughput and practical tolerance control for structural components where speed and process economy are top priorities.
Advantages: High cutting speed, lower operating cost, and strong thick-metal capability.
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Punching forms holes and cutouts by driving a punch through sheet stock into a matching die, creating repeatable features with efficient cycle times.
It is effective for repeated patterns and perforated layouts, and performs best when the feature diameter is appropriately larger than material thickness.
Advantages: Fast production, economical tooling, and repeatable perforation quality.
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Chemical etching removes metal through a controlled mask-and-etch process instead of mechanical force, making it useful for thin decorative and functional sheet details.
It is a good fit for fine speaker grilles, anti-insect screens, filter meshes, nameplates, logo plates, and textured metal surfaces where clean openings and low burr risk matter.
For automotive trim or consumer hardware, etching can be combined with brushing, plating, painting, or PVD-style finishing when the part needs both pattern accuracy and a controlled surface look.
Advantages: Fine pattern control, low tooling pressure, low burr risk, and strong fit for thin metal details.
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Some sheet metal parts do not need a heavier forming route. For thin stainless steel or aluminum details, etching can produce repeatable openings, textures, and branding features while keeping the part flat and clean.

Fine openings and repeated graphic details can be controlled without the stress that punching can add to delicate sheet stock.
Etched parts can move into brushing, plating, painting, or other visible finishes when the part sits on an interior or exterior surface.
Open area, airflow, filtration, and sound passage can be reviewed together instead of treating the mesh as only a cosmetic insert.
2D/3D measurement, color review, salt spray, hardness, and visual checks can be added when the program needs documented acceptance.
Within our Manufacturing Service, bending forms V, U, and channel profiles using a press brake with controlled force and angle targets based on material thickness and strength.
Because elastic recovery can change final geometry, we apply over-bend compensation for springback so finished parts match drawing intent more consistently.
Bending is widely used for enclosures, brackets, and structural sheet components that require repeatable angular accuracy.
Advantages: Cost-efficient forming, high repeatability, and compatibility with various metals.
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Stamping is a high-speed deformation process that uses mechanical or hydraulic dies to shape sheet stock for repeatable production output.
It supports coining, curling, hemming, and ironing operations, allowing stable feature creation for programs that require tight part-to-part consistency.
This approach is especially effective for higher-volume production where cycle time and repeatability are primary constraints.
Advantages: Fast cycle time, precise detail, and strong suitability for production-scale volumes.
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Spinning forms hollow and rotationally symmetric parts by rotating a metal blank on a lathe and progressively pressing it against a shaped tool.
The process can be manual or mechanically assisted depending on geometry complexity and output requirements.
It is commonly selected for cones, hemispheres, and cylindrical forms where smooth surfaces and stable symmetry are required.
Advantages: Smooth finishes, lower tooling cost, and strong fit for rounded geometries.
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Assembly is the final stage of sheet metal fabrication where multiple parts are combined into a complete functional product.
After cutting, forming, and surface preparation, components are joined with fasteners, rivets, welds, or other standard methods based on performance and service requirements.
As a Metal Processing Company, we support both manual and automated assembly planning for multi-part industrial structures.
Advantages: Product readiness, design flexibility, and support for manual or automated methods.
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Welding fuses sheet metal components through controlled heat input to create strong and permanent joints for structural and enclosure applications.
Materials such as aluminum and stainless steel can be joined through TIG, MIG, or spot welding depending on thickness, joint geometry, and quality targets.
This process is typically scheduled after forming and before final finishing to preserve structural integrity throughout downstream operations.
Advantages: Strong joints, permanent bonding, and compatibility with multiple metals.
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Choosing the right manufacturing method is key to achieving target part quality. Not sure which method best fits your program?
Contact UsWith fast lead times, no minimum order volume, and low per-unit cost at early stages, rapid sheet metal is a practical option for functional prototyping and iterative validation.
Learn MoreLow-volume production programs around 100K parts can speed up market entry. As a Machinery Parts Manufacturer, ZigiTech delivers custom metal parts with stable quality for this phase.
Learn MoreFollow practical design rules to improve manufacturability, structural integrity, and cost efficiency in sheet metal Manufacturing Service programs.
| Feature | Recommended Value (MT = Material Thickness) | Notes |
|---|---|---|
| Minimum Bend Radius | 1 x MT | Avoid cracking (may vary by material: soft aluminum <= 0.5 x MT, stainless steel >= 2 x MT). |
| Hole-to-Edge Distance | 2 x MT | Prevents edge deformation during punching. |
| Hole-to-Hole Distance | 6 x MT | Ensures structural integrity (increase for dense hole patterns). |
| Bend-to-Hole Distance | 6 x MT | Prevents hole distortion during bending. |
| Feature-to-Countersink Distance | 8 x MT | Maintains material strength around countersinks. |
| Minimum Countersink Depth | 0.6 x MT | Ensures flush fastener seating (adjust for screw head angle). |
| Relief Cut Width | 1 x MT | Reduces stress concentration at bends (required for sharp corners). |
| Corner Fillet Radius | 0.5 x MT | Improves manufacturability and stress distribution. |
The feedback during quoting helped us fix a problem before release rather than after samples. That saved time we really did not have in the program.
Ora teniamo Zigitech tra i fornitori ogni volta che un programma richiede revisione rapida, comunicazione chiara e consegne affidabili all'estero. Sono stati costanti su diversi ordini.
Vi bestilte aluminiums manifolder til en pilotproduksjon og fulgte tetningsflatene nøye. Delene kom godt pakket og klarte inngående kontroll uten anmerkninger.
What stood out was that the quote review connected design choices to production reality. Our team got clear notes on wall thickness, access, and finish instead of vague suggestions.
Pro program rozvaděčů odpovídaly osazení kování a detaily ohnutí schválené výkresové sadě bez překvapení. Ušetřilo to přepracování na naší montážní straně.
We asked for a tooling review before final approval and got specific comments on shutoffs and cosmetic risk. It felt like feedback from people who actually build these parts.
The turned shaft parts were consistent from sample to sample, which mattered because we were checking fit against bearings and seals. That repeatability is hard to fake.
Mielismy jedno pytanie dotyczące materiału w trakcie zamówienia i otrzymaliśmy prostą odpowiedź z opcjami, a nie opóźnioną odpowiedź sprzedażową. To pomogło nam utrzymać ruch w wewnętrznych akceptacjach.
프로토타입 커버는 고객 데모용으로 보여주기 충분할 만큼 깔끔했고, 동시에 실제 핏 확인에도 사용할 수 있었습니다. 그 단계에서 우리가 딱 필요로 했던 균형이었습니다.
Across a mixed order of parts and jigs, revision control stayed clear all the way through. That made our own internal tracking much easier when the shipment landed.
The feedback during quoting helped us fix a problem before release rather than after samples. That saved time we really did not have in the program.
Ora teniamo Zigitech tra i fornitori ogni volta che un programma richiede revisione rapida, comunicazione chiara e consegne affidabili all'estero. Sono stati costanti su diversi ordini.
Vi bestilte aluminiums manifolder til en pilotproduksjon og fulgte tetningsflatene nøye. Delene kom godt pakket og klarte inngående kontroll uten anmerkninger.
What stood out was that the quote review connected design choices to production reality. Our team got clear notes on wall thickness, access, and finish instead of vague suggestions.
Pro program rozvaděčů odpovídaly osazení kování a detaily ohnutí schválené výkresové sadě bez překvapení. Ušetřilo to přepracování na naší montážní straně.
We asked for a tooling review before final approval and got specific comments on shutoffs and cosmetic risk. It felt like feedback from people who actually build these parts.
The turned shaft parts were consistent from sample to sample, which mattered because we were checking fit against bearings and seals. That repeatability is hard to fake.
Mielismy jedno pytanie dotyczące materiału w trakcie zamówienia i otrzymaliśmy prostą odpowiedź z opcjami, a nie opóźnioną odpowiedź sprzedażową. To pomogło nam utrzymać ruch w wewnętrznych akceptacjach.
프로토타입 커버는 고객 데모용으로 보여주기 충분할 만큼 깔끔했고, 동시에 실제 핏 확인에도 사용할 수 있었습니다. 그 단계에서 우리가 딱 필요로 했던 균형이었습니다.
Across a mixed order of parts and jigs, revision control stayed clear all the way through. That made our own internal tracking much easier when the shipment landed.
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