How much does it cost to fabricate metal parts?
If you’re in the manufacturing, automotive, aerospace, or robotics industry, you’ve probably asked this critical question: How much does it cost to fabricate metal parts? The short answer is there’s no universal figure—metal part fabrication costs depend heavily on material choice, design complexity, production volume, and machining processes.
As a factory-direct CNC machining service provider with over 10 years of experience, we’re breaking down the key cost drivers, real-world examples, and practical tips to help you budget accurately and cut unnecessary expenses. Whether you’re prototyping a new component or ordering bulk parts, this guide will clarify what impacts your costs—and how to optimize them.
1. Core Factors That Determine Metal Fabrication Costs
Before looking at specific numbers, it’s vital to understand the variables that shape your project’s budget. These factors often interact: for example, a complex design might require more expensive materials or longer machining time. Balancing them is the key to cost efficiency.
▶ a. Material Selection: The Biggest Cost Foundation (20%-40% of Total Costs)
The metal you choose makes up 20%-40% of your total fabrication costs—this is because different metals vary drastically in price, machinability, and performance. Below are the most common metals we work with, along with their 2024 average cost ranges (per kilogram, FOB our China factory), key use cases, and machinability:
Note: Metal prices fluctuate with global markets (e.g., iron ore, aluminum ingot) and shipping costs. For bulk orders (500kg+), we offer 5%-15% material discounts.
▶ b. Design Complexity: Simple vs. Intricate (Affects Machining Time)
A part’s design directly impacts how long it takes to machine—and thus labor costs. Here’s how complexity breaks down for CNC machining projects:
● Simple Parts: Basic shapes (e.g., flat metal sheets, cylindrical rods) with no holes or curves.
Machining time: 1-2 hours
Cost range: $50 - $200 per part
● Medium Complexity: Parts with 2-5 holes, simple threads, or minor contours (e.g., custom mounting brackets, small gears).
Machining time: 3-8 hours
Cost range: $200 - $800 per part
● High Complexity: Precision parts with tight tolerances (±0.001”), 3D contours, or multiple features (e.g., aerospace engine components, medical device parts).
Machining time: 10-40+ hours
Cost range: $800 - $5,000+ per part
Pro Tip: Get a free DFM (Design for Manufacturability) review! Our engineering team often suggests small tweaks—like adjusting hole spacing or simplifying a non-critical curve—that cut costs by 15%-30% without compromising performance.
▶ c. Production Volume: Economies of Scale (Lowers Per-Part Costs)
Volume is one of the most impactful cost drivers. Small batches require more setup time (e.g., calibrating CNC machines, programming toolpaths), while large batches spread these fixed costs across more parts. Below is a real example using an Aluminum 6061 bracket (medium complexity) to show how volume affects costs:
Our Advantage: For volumes over 1,000 parts, we use dedicated CNC cells (optimized for your specific part) to reduce per-part costs by an extra 10%-20%.
▶ d. Machining Processes: Choose the Right One for Your Part
The process used to fabricate your part affects both cost and quality. We specialize in CNC machining (milling, turning) and supplementary processes like laser cutting and surface finishing—here’s how they compare in terms of hourly costs and best uses:
● CNC Milling: Ideal for 3D parts with complex features (e.g., brackets with multiple holes, 3D-contoured components).
Cost: $60 - $120 per hour
● CNC Turning: Best for cylindrical parts (e.g., shafts, bolts, pins) that need precision on outer/inner diameters.
Cost: $50 - $100 per hour
● Laser Cutting: Fast and cost-effective for flat metal sheets (up to 20mm thick, e.g., sheet metal enclosures, flat brackets).
Cost: $40 - $80 per hour
● Surface Finishing: Adds $5 - $50 per part (depending on the process):
Anodizing (for aluminum): $8 - $15 per part
Powder coating (for steel/aluminum): $10 - $25 per part
Passivation (for stainless steel): $7 - $12 per part
2. Real-World Metal Fabrication Cost Examples
To make these numbers concrete, let’s look at three recent projects we completed—each with different materials, volumes, and budgets.
▶ Example 1: Automotive Aluminum Bracket (Small Batch)
● Part Details: Aluminum 6061, 50mm x 30mm x 5mm, 2 holes, anodized finish (black)
● Production Volume: 20 parts
● Total Cost: $1,800 ($90 per part)
● Cost Breakdown:
Material: $2.80/kg x 0.5kg per part = $1.40 per part
Machining: 2 hours x $70/hour = $70 per part
Finishing: $15 per part
Setup: $300 (total, spread across 20 parts = $15 per part)
▶ Example 2: Stainless Steel Medical Component (Medium Batch)
● Part Details: Stainless Steel 316, precision threads (±0.002”), passivated finish (for corrosion resistance)
● Production Volume: 100 parts
● Total Cost: $12,500 ($125 per part)
● Cost Breakdown:
Material: $6.50/kg x 1kg per part = $6.50 per part
Machining: 4 hours x $90/hour = $108 per part
Finishing: $10.50 per part
Setup: $500 (total, spread across 100 parts = $5 per part)
▶ Example 3: Titanium Aerospace Part (Prototyping)
● Part Details: Titanium Grade 5, 3D contours, tight tolerance (±0.001”), no additional finish
● Production Volume: 2 parts
● Total Cost: $4,800 ($2,400 per part)
● Cost Breakdown:
Material: $45/kg x 2kg per part = $90 per part
Machining: 25 hours x $120/hour = $2,250 per part
Setup: $500 (total, spread across 2 parts = $250 per part)
3. 4 Practical Tips to Reduce Metal Fabrication Costs
Working with a factory-direct CNC machining provider (like us) gives you access to cost-saving opportunities that middlemen can’t offer. Here are our top recommendations to lower your project costs:
1. Optimize Material Usage
We nest parts on metal sheets (for laser cutting) to minimize waste—this can reduce material costs by 10%-15%. We also suggest cheaper material alternatives when possible: for example, using Aluminum 6061 instead of Titanium Grade 5 for non-high-temperature, non-aerospace parts.
2. Simplify Design (Without Sacrificing Quality)
Our free DFM reviews flag unnecessary features that add cost:
Over-tight tolerances (e.g., ±0.001” when ±0.005” works)
Complex curves that take longer to machine
Unneeded holes or threads
3. Plan for Higher Volume (Even If You Don’t Need It Now)
Even if you only need 10 parts today, ordering 50 (and storing the extra) can cut per-part costs by 30% or more. For example, an Aluminum 6061 bracket costs $150 per part for 10 units, but only $80 per part for 50 units.
4. Combine Processes In-House
If your project needs multiple steps (e.g., milling + laser cutting + anodizing), we handle everything in our factory. This eliminates shipping costs between suppliers and reduces lead time by 20%-30%.
4. Get a Custom Metal Fabrication Quote (Free, No Obligation)
Every metal fabrication project is unique—and so is our pricing. To get an accurate quote, share these details with our team:
● 2D/3D CAD files (STEP, IGES, or DWG format—we can also help with design if you don’t have files)
● Material preference (or let us recommend the best option for your use case)
● Production volume (prototyping, small batch, or large scale)
● Surface finish requirements (e.g., anodizing, powder coating)
● Tolerance needs (e.g., ±0.005”)
We respond within 24 hours with a detailed quote—including a breakdown of material, labor, and setup costs. For urgent projects (1-3 day turnaround), we offer expedited services at a 20%-30% premium.
At F&Q-tech, we believe in transparency: no hidden fees, no surprise cost hikes. Whether you’re a startup prototyping a new product or a large manufacturer needing bulk parts, our CNC machining expertise and factory-direct pricing will help you get the best value for your budget.
Contact us today to start your project:
Email: lyy@fsqj-tech.com | Tel / WhatsApp: +86 136 1605 5490
