Interesting Facts About the History, Science, & Industry of Sheet Metal
Sheet metal is one of the most important and versatile materials made today. It is utilized by the defense, housing, auto, medical, aero, and green energy industries, and many more not listed.
Sheet metal has ancient origins, but is an ever evolving industry that is vital to our modern world. Sheet metal fabrication relies on cutting-edge science and the hard work of millions of sheet metal workers.
The history, science, and modern-day industry of sheet metal fabrication is interesting and important to those curious about manufactoring and innovation. Here are 11 sheet metal facts you need to know.
1) Sheet metal fabrication has ancient origins.
The ancient Egyptians first used sheet metal to craft fine jewelry. The processes used were obviously much different than those utilized in sheet metal fabrication shops today, but the Egyptians get credit being the first to create thin sheets of flexible, light weight metal.
2) Leonardo da Vinci sketched the first metal rolling mill.
Leonardo da Vinci was often ahead of the times as an artist and inventor. His contributions to sheet metal production were no exception. Da Vinci sketched his idea for a rolling mill in the 1480s, and the first rolling mills were finally developed two centuries later in the 1600s.
The first rolling mills were utilized in the coin making industry. Gold and silver coins could be made quickly from uniform sheets that were run through the mills.
3) Before the invention of modern processes, sheet metal was made through “puddling.”
Metal workers in the 18th century employed a process called “puddling.” This involved heating cast iron in furnaces until liquefied. The major problem with this method was that almost half of the iron was drawn off with the slag.
This made puddling rather inefficient compared to methods developed in the 19th century and onwards.
Despite its inefficiency, puddling was the common way metal workers manipulated metal in the early days of the Industrial Revolution. The process was even used to make the Statue of Liberty and the Eiffel Tower.
4) Jean Pierre Droz made sheet metal manufacturing what it is today.
Jean Pierre Droz was a Swiss coin and metal engraver who worked at the Paris Mint during the late 18th and early 19th centuries. He is remembered for developing the Napoleon coin during the reign of Napoleon Bonaparte.
In the late 18th century, Droz worked with Englishman Matthew Boulton to improve the quality of his coinage. Droz’s techniques ensured uniforming sizing and engraving, and his methods were transferred to sheet metal production at the start of the Industrial Revolution.
5) Metal punching was first developed in the mid 1800s.
Punching is an essential step for sheet metal that will be riveted or screwed together. The process has evolved since its development in the 19th century.
Manufacturers began punching metal in 1847 after bridge workers realized uniform and strategically placed holes would be helpful for installing metal components.
6) Sheet metal undergoes different finishing processes depending on its intended use.
Depending on how the sheet metal will be used, certain finishing processes are utilized to ensure maximum quality and durability.
Galvanization prevents the corrosion of metal. This process involves coating sheet metal with zinc.
Annealing improves the workability of sheet metal and happens through heat treatment.
Anodizing is a process in which aluminum is applied to metal to protect against wear and tear.
Tinning is used on food cans and other metals that come in contact with food. It prevents the oxidation of metal.
Tempering involves heating and cooling metal to increase its durability.
7) There are several ways to cut sheet metal.
Depending on the type of product being manufactured, sheet metal fabricators will choose from a few methods of cutting.
Fabrication shops can snip, punch, laser cut, plasma cut, or oxygen cut sheet metal. Laser and plasma cutting are common methods in sheet metal fabrication today.
8) Sheet metal roofing can be made from a few different materials.
While aluminum or steel are popular choices for metal roofing, other common metals used in the manufacturing of roofing include copper, zinc, iron, and lead.
Each metal lends its own characteristics the final roofing product, and manufacturing companies choose from these materials based on their desired look, weight, and level of durability.
9) Sheet metal is made in a range of thicknesses.
The term “sheet metal” may bring to mind metal that is paper thin, but sheet metal is actually produced in a number of thicknesses depending on how it will be used.
The average sheet metal produced in most fabrication shops today range in thickness from 1.5 mm to 6 mm. As a general rule, sheet metal does not exceed a thickness of 14 mm.
For most uses, sheet metal needs to be thin and flexible, yet durable. Metal that is thicker or thinner than the measurements described above will be too thick to manipulate, or too fragile to withstand fabrication and use.
10) Sheet metal fabrication shops are common across the United States.
Whether you reside in a small town or a large city in America, chances are there is a sheet metal fabrication shop near you. The United States alone has close to 615,000 workshops dedicated to sheet metal manufacturing!
The number rises when factoring in other types of metal production, and fabrication shops that work on both sheet metal and other products.
11) The sheet metal industry is valuable and growing.
Today, sheet metal is a major industry in the United States and around the developing world. Since sheet metal is used in a wide range of industries, sheet metal fabrication is vital to the economy.
In 2020, the sheet metal industry was worth $3.8 billion. The value of the industry is projected to grow to over $4.3 billion by 2027.
Sheet metal fabrication is both an ancient and excitingly evolving process with a bright future.