How to Knock 30% Off Your Next Sheet Metal Fabrication Quote Without Changing the Material

Looking to reduce your sheet metal fabrication costs without compromising on quality or switching materials? Every year, thousands of engineers and buyers across the United States, Europe, and Australia search for ways to stretch their custom sheet metal parts budget. Here are seven practical tactics you can apply today to cut up 30% from your next quote.

           ●  Part geometry & design complexity

           ●  Processes required (laser cutting, bending, welding, finishing)

           ●  Tolerance & precision requirements

           ●  Material utilization & nesting efficiency

           ●  Batch size & production schedule

           ●  Surface finish & assembly details

           ●  Eliminate unnecessary features

           ●  Consolidate multi-part assemblies into one piece

           ●  Use standard bend radii (≈ material thickness)

           ●  Minimise bend count-each bend adds cost

           ●  Match your design to standard tooling

"We regularly help customers reduce costs by 20-30% simply by optimizing their designs for our manufacturing processes," says a senior engineer at our facility.

Custom punches = custom cost. Stick to common diameters (3, 4, 5, 6, 8, 10, 12 mm) and radii that match off-the-shelf tooling.

           ●  Combine different parts on the same sheet

           ●  Use full-sheet sizes (1220 x 2440 mm or 48" x 96")

           ●  Design common edges to improve yield

           ●  Respect grain direction for bent components

Over-tolerancing can raise cost 50-100 %. Use these guidelines unless function forbids:

           ●  Laser cut: ±0.1-0.2 mm

           ●  Bend angle: +0.2-0.5 mm

           ●  General dim: ±0.5 mm

Riveting or press-fit fasteners can be 30-50 % cheaper than welding. When welding isunavoidable, minimise length and use intermittent welds where strength allows.

           ●  Call out finish only on visible/functional faces

           ●  Select standard powders, anodise or plating specs

           ●  Batch parts together to cut set-up cost

           ●  Order several parts in one batch (50-500 pc sweet spot)

           ●  Standardise material grades across parts

           ●  Consider blanket orders for recurring demand

An Australian electronics client redesigned an aluminium enclosure:

           1. Removed 3 non-critical bends

          2. Standardised all holes to 4 mm & 6 mm

          3. Merged 4 parts into 2

          4. Relaxed tolerance from ±0.1 mm to ±0.3 mm on non-critical dims

          5. Switched welds to rivets

Result: 32 % cost reduction with zero loss of performance.

           ●  Designing in isolation from the shop

           ●  Global tight tolerances

           ●  Custom fasteners & hardware

           ●  Ignoring material grain

           ●  Over-complex geometry

           1. Audit existing prints against the checklist above

          2. Engage your fabricator early for a free DFM review

          3. Pilot changes on one or two parts

          4. Roll out successful tweaks across the product line

Knocking 30 % off your sheet metal fabrication quote isn't magic-it's method. Optimise design, standardise features, tolerate wisely, and partner with a fabricator who offers transparent DFM input. Start today and watch your next quote drop.