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Sheet metal
Sheet metal prototypes and low-volume production
Sheet metal prototypes and low-volume batches need no tooling, so you can test fit, revise the design and build again without paying for die changes. We fiber laser cut sheet up to 1500 × 3000 mm, CNC bend up to 3 m and laser weld in-house. When a part reaches stamping volumes, we quote the break-even point for a die.
Key specs at a glance
| Processes | Fiber laser cutting, CNC bending, laser welding |
|---|---|
| Tooling | None for laser cut and bent parts |
| Max sheet | 1500 × 3000 mm, up to 20 mm thick |
| Bend length | Up to 3 m |
| Quantities | Prototype and low-volume batches |
| Finishing | Powder coat, paint, plating, brushing via partners |
| Sample cost and lead time | Confirmed per project in the quote |
Why prototype in sheet metal before tooling?
A progressive die is the cheapest way to make a part at volume, but it locks the design. Laser cutting and press-brake bending need only a CNC program, so you can test fit, assembly and function, change the design and build again without paying for die changes.
For many enclosures, cabinets and brackets, laser cut and bent parts are also the final production method: at a few hundred or a few thousand pieces a year, there is no reason to build a die at all.
Prototype, bridge batch, production: how the stages differ
| Stage | Purpose | Process | Inspection |
|---|---|---|---|
| Prototype | Check fit, form and function | Laser cut, CNC bent, laser welded | Key dimensions against the drawing |
| Bridge / pilot batch | Supply early builds while the design settles | Same, with fixtures where useful | First article report, then AQL sampling |
| Production | Stable design and volume | Sheet metal, or stamping if volume justifies a die | First article, AQL sampling and 100% checks on critical features |
When should a part move from sheet metal to stamping?
Move when the tooling cost spread over the parts you will buy is less than what you save per piece. That point depends on part size, thickness and annual volume. Our stamping lines take strip from 0.15 to 1.2 mm with an order minimum of 1,000 pieces; thicker or larger parts usually stay as laser cut and bent sheet metal.
If you expect to stamp later, tell us at the prototype stage. We will keep features that a die can produce — consistent bend radii, holes not too close to bends, no features that only a laser can cut — so the move does not force a redesign.
Design rules for fast prototypes
Rules of thumb that keep prototype parts quick to make; t is sheet thickness.
- Use one inside bend radius across the part, ideally close to the sheet thickness, so one tool set does all bends.
- Keep holes and slots at least 2 × t plus the bend radius away from bend lines.
- Make flanges long enough to sit on the press-brake die — at least about 3 × t, more on thick sheet.
- Add bend reliefs where a bend ends at an edge.
- Use standard sheet thicknesses for the grade; odd gauges can take longer to source.
- Apply general tolerances (JIS B 0408 or ISO 2768) and put tight tolerances only on mating features.
What we need to quote a prototype
- STEP model (preferred) or DXF flat patterns plus a PDF drawing
- Material, thickness and finish
- Prototype quantity and the expected production volume
- Which dimensions are critical for fit
- Whether you expect to stamp the part later
Checking prototype parts
Prototype parts are checked against your drawing for the dimensions you mark as critical, on the vision measuring system for small parts and with height gauges and fixtures for larger ones. Ask for a first article report and the prototype can serve as the reference for production.
Frequently asked questions
Is there a minimum order for sheet metal prototypes?
Laser cut and bent parts need no tooling, so we quote prototype quantities. The 1,000-piece minimum applies to stamped parts.
How long does a sheet metal prototype take?
It depends on part complexity, finishing and material availability. Lead time and sample cost are confirmed per project in the quote.
Can you powder coat prototypes?
Yes, through our finishing partners. Small prototype batches can be coated, but color, texture and batch timing are confirmed in the quote.
Will the prototype match production parts?
If production stays in sheet metal, yes — the same programs and processes are used. If production moves to stamping, the die may change small features such as corner radii, and we tell you which ones before tooling.
Can you build a full cabinet as a prototype?
Yes. Cabinets up to 3000 mm tall and 1500 mm wide can be built as single prototypes.
Related pages
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