How to Reduce Costs in Sheet Metal Fabrication Projects

Design
Written By Bjorn Thompson

Sheet metal fabrication is a critical part of many manufacturing and construction projects—but costs can add up quickly if the process isn’t planned carefully. From material selection to design choices and production methods, small decisions can have a big impact on your final price. Below are practical, proven ways to reduce sheet metal fabrication costs without sacrificing quality or performance.

1. Optimize Your Design for Manufacturability (DFM)

One of the most effective ways to lower fabrication costs starts before production even begins. Designing parts with manufacturability in mind helps reduce labor time, tooling changes, and material waste.

  • Avoid unnecessary bends and complex geometries

  • Use standard hole sizes and bend radii

  • Maintain consistent material thickness

Following basic DFM (Design for Manufacturing) principles can significantly reduce setup time and rework, leading to faster and more affordable production.

2. Choose the Right Material

Material choice directly affects both material cost and processing time. While stainless steel may be necessary for some applications, aluminum or mild steel could offer the same performance at a lower price.

To reduce costs:

  • Select the lowest-grade material that still meets performance requirements

  • Consider availability—readily stocked materials are cheaper

  • Avoid exotic alloys unless absolutely necessary

An experienced fabricator can help you balance cost, strength, corrosion resistance, and appearance.

3. Use Standard Thicknesses and Gauges

Non-standard material thicknesses often increase costs due to special ordering and added waste. Using standard sheet metal gauges allows fabricators to optimize nesting and reduce scrap.

Standardization also improves:

  • Faster lead times

  • Lower material prices

  • Reduced tooling adjustments

Whenever possible, align your design with industry-standard sizes.

4. Reduce Secondary Operations

Secondary operations such as welding, grinding, tapping, and finishing add labor and time. Reducing or eliminating these steps can dramatically cut costs.

Cost-saving strategies include:

  • Designing parts that self-locate or snap together

  • Using formed features instead of welded components

  • Minimizing cosmetic finishes where they aren’t visible

Less handling means fewer labor hours—and lower invoices.

5. Plan for Efficient Production Volumes

Prototype and low-volume jobs are typically more expensive per unit due to setup costs. If possible:

  • Combine multiple parts into one production run

  • Increase order quantities for better economies of scale

  • Schedule repeat orders to reuse tooling and setups

Even small volume increases can lead to noticeable cost savings.

6. Work with the Right Fabrication Partner

Choosing a knowledgeable sheet metal fabrication partner can save money in the long run. A good fabricator will:

  • Suggest design improvements

  • Identify cost-saving alternatives

  • Prevent costly mistakes before production

Early collaboration often results in better pricing, higher quality, and shorter lead times.

Final Thoughts

Reducing costs in sheet metal fabrication isn’t about cutting corners—it’s about making smarter decisions at every stage of the project. By optimizing design, selecting the right materials, minimizing secondary operations, and partnering with an experienced fabricator, you can achieve high-quality results while staying within budget.

If you’re planning a new project, consulting with a sheet metal fabrication expert early can be one of the smartest cost-saving moves you make.

Bjorn Thompson
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