Sheet metal fabrication

Overview

Laser cut, formed and finished in-house

Sheet metal fabrication is the core of our fabrication department. We cut, punch, form, roll, weld, install hardware and finish, all in one building, so nothing waits on an outside vendor.

Every part starts on 24/7 automated CO2 and fiber lasers that nest your geometry for clean edges and minimal scrap. Formed features are bent on 220-ton NC press brakes, hardware is pressed in, and outside finishing such as powder coat, plating and paint is coordinated for you. This is a natural part of our wider metal fabrication service.

Punching, rolling and hardware, not just cutting

Sheet metal fabrication here goes well beyond the laser. A turret punch adds features a laser cannot cut as cheaply at volume, a plate roller curves flat stock into cylinders and cones, and hardware presses seat fasteners without a separate operation.

• NC turret punchingUp to a 33-ton turret punch, including a combination punch/laser cell for parts that need both processes in one setup.
• Plate rollingUp to 48 in wide, for curved panels, cylinders and cones a press brake cannot form.
• Hardware pressingAutomatic presses up to 16,000 lbs capacity and a 24 in throat seat PEM and other self-clinching fasteners to spec.

Works alongside tube laser cutting and welding

Sheet and tube share the same fabrication floor. Cut sheet metal parts move straight into tube laser cutting for matching frame components, or into welding to become a finished assembly, without leaving the building. For the full picture of everything we fabricate, see metal fabrication.

Materials we fabricate

We work in a range of metals, from workhorse mild steel to corrosion-resistant stainless, and will help you choose the most cost-effective option for the job during quoting and DFM review. Not sure what fits? Tell us the load, environment and finish the part needs to handle and we will recommend one.

• Mild & carbon steelStrong, weldable and economical, mild and carbon steels are our workhorse metals for brackets, frames, base plates and general structural parts where raw strength matters more than corrosion resistance.
• Stainless steelStainless steel resists rust and stands up to harsh, wet and sterile conditions, which makes it the right choice for medical, food-grade, marine and outdoor hardware that has to stay clean and last for years.
• AluminumLightweight yet rigid, aluminum cuts and forms fast to a clean finish and sheds heat well, so it is ideal for enclosures, panels and other weight-sensitive assemblies.
• Copper & brassCopper and brass conduct electricity well and finish cleanly, making them well suited to connectors, bus bars, terminals and precision fittings.
• Other metals on requestWorking with a different alloy? Tell us what you need and we will confirm we can fabricate it and help you choose the most cost-effective option for your part.

Sheet metal specifications

Real, in-house capacity across cutting, punching, forming and finishing, backed by a fleet of 4 lasers, 3 turret punches, 6 press brakes/rollers and 5 automatic hardware presses. Bring us a challenging part and we will tell you exactly how, and on which machine, we would make it.

Our sheet metal fabrication process

Every job follows the same controlled path, from first quote to final inspection, so parts come off the line accurate, repeatable and ready for the next step whether you order one part or ten thousand.

1. Quote & DFM reviewSend drawings or CAD. We review the design for manufacturability, flag any changes that would lower cost or improve tolerance, and send back a fast, honest quote.
2. Laser & punchParts are nested and cut across our 4 automated laser cutting cells and 33-ton CNC turret punches, running 24/7 for clean edges and real material savings.
3. Form & roll220-ton NC press brakes and rolling equipment bend parts to print on a 14 ft bed, with the first article checked against the drawing before the rest of the run follows.
4. Hardware & weldPEM and other self-clinching hardware is pressed in on our automatic presses, and certified welders join assemblies where the design calls for it.
5. FinishGrain sanding, polishing and automated burr removal happen in-house, and outside finishing such as powder coat, plating or paint is coordinated so you get one shipment, not two.
6. Inspect & shipLaser quality inspection confirms every critical dimension, then parts are packaged and shipped direct to you or moved straight into machining and assembly.

Finishing & secondary operations

A fabricated sheet metal part is rarely the finished product. As a one-stop Texas shop we handle the steps that usually mean another vendor and another shipment:

• CNC machiningSheet metal parts that need close-tolerance holes, bores or mating features move straight to our machining floor, in the same buildings.
• Coating & finishingAutomated dry and wet surface finishing lines and burr-removal equipment handle deburring in-house, and we coordinate powder coat, plating and paint so parts arrive fully finished.
• Hardware installationPEM and other self-clinching hardware, inserts and fasteners are installed to spec as part of the fabrication run, not a separate order.
• Assembly & box buildFinished sheet metal fabrications are built into electro-mechanical sub-assemblies and complete product builds, all under one roof.

Industries we fabricate for

Star Precision fabricates sheet metal parts for demanding Texas and national manufacturers, including the regulated and heavy-industrial sectors below, where certified quality and material traceability matter as much as the part itself:

• Oil, gas & energyWe fabricate durable, corrosion-resistant sheet metal enclosures and structures for power generation and oil, gas and energy equipment.
• Aerospace & spaceWe fabricate laser-cut brackets, chassis and structural hardware for aerospace and space customers across the NASA and JSC region.
• Defense & militaryWe fabricate ruggedized sheet metal enclosures and assemblies to demanding defense and military specifications.
• Industrial & OEMWe fabricate laser-cut and formed frames and sub-assemblies for industrial and OEM equipment makers.
• Architectural metalsWe fabricate canopies, panels and feature metalwork built to elevate design, like our El Paso airport art canopy.
• Solar & alt energyWe fabricate laser-cut mounting systems and enclosures for renewable installations.

What to expect when you work with us

Working with a fabrication shop should be straightforward. From the first file you send to the finished parts arriving on your dock, here is what you can count on from our team.

• Send a flat pattern or a sampleA STEP, IGES, DXF/DWG or PDF file works, or send a physical part and we will nest, punch and form directly from it.
• Fast, honest quotesQuotes come back quickly, with DFM notes on hole placement, bend relief and tolerances that can save material before we cut.
• One point of contactOne team owns your job from cutting through finishing and assembly, all under one roof.
• NDAs on requestWe sign NDAs on request, so your part drawings and specs stay fully confidential.
• On-time deliveryAutomated 24/7 laser cutting and in-house forming keep parts moving, so delivery stays dependable, not stuck on an overseas queue.

Sheet Metal Fabrication FAQs

Quick answers about our sheet metal fabrication services. Company-wide questions are covered in the FAQs at the bottom of the page.

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