Calculate comprehensive sheet metal fabrication costs including material, bending, cutting, welding, and finishing operations for precise project estimates.
Material Specifications
mm
Cost of standard 4x8 sheet (1220x2440mm)
Surface Area: 0.10 m² |
Volume: 0.00015 m³ |
Weight: 1.18 kg
Fabrication Processes
Perimeter + internal cutouts
Optimize material usage
Bend Allowance Calculation
Typical: 0.33-0.5 (0.42)
2.67 mm
Material needed per bend
Selected Processes: Laser Cutting, Bending |
Estimated Setup Time: 25 minutes
Cost Parameters & Quantity
Number of identical parts
Average fabrication shop rate
Scrap, kerf, errors
Sheet Metal Fabrication Cost Analysis
Cost Per Part
$8.75
Total Project Cost
$875.00
Production Time
10.3 hours
Detailed Cost Breakdown
Material Cost
$3.15
Raw material per part
Fabrication Cost
$4.12
Cutting, bending, labor
Finishing Cost
$1.08
Surface treatment
Profit Margin
$2.02
Business profit
Production Time Analysis
Cost Distribution
Quantity Pricing Analysis
Design for Manufacturing Tips
Based on your design, consider increasing bend radii to reduce springback and improve consistency. Nesting efficiency can be improved by 15% with minor dimension adjustments.
Manufacturing Method Comparison
Related Calculators
Frequently Asked Quentions
1. How much does sheet metal fabrication typically cost per hour?
2. What is the most cost-effective sheet metal material for fabrication?
Mild steel (CRS) is generally the most cost-effective at $25-45 per square meter, followed by galvanized steel at $30-50 per square meter. Aluminum 5052 provides excellent value at $35-60 per square meter when weight reduction or corrosion resistance is important. Material choice should balance cost with functional requirements.
3. How does material thickness affect fabrication costs?
Costs increase disproportionately with thickness. Doubling material thickness typically increases material costs by 80-120%, cutting time by 60-100%, and bending effort by 70-110%. The optimal thickness balances structural requirements with manufacturing economics.
4. What's the minimum order quantity for sheet metal fabrication?
Most fabricators have minimum orders of $250-500 for prototypes and $500-1,000 for production quantities. Laser cutting services may accept smaller orders starting at $100-250. High-volume manufacturers typically require $1,000-5,000 minimum orders but offer better per-part pricing.
5. How accurate are sheet metal fabrication cost estimates?
Professional cost estimates are typically within 10-15% of final costs for standard projects. Complex projects with multiple processes may have 15-25% variance. The most accurate estimates come from detailed CAD models with complete specification of materials, tolerances, and finishes.
6. What is the K-factor in sheet metal bending?
The K-factor represents the neutral axis position in bent sheet metal, typically ranging from 0.3 to 0.5. It determines bend allowance calculations for accurate flat pattern development. Mild steel commonly uses 0.42, stainless steel 0.44, and aluminum 0.38-0.42 depending on alloy and temper.
7. How long does typical sheet metal fabrication take?
Prototype delivery: 1-3 weeks Small production runs (50-500 units): 3-6 weeks Large production runs (500-5,000 units): 6-12 weeks Rush prototyping: 3-7 days (typically 50-100% premium)
8. What are the most expensive sheet metal fabrication processes?
Complex bending setups and multi-axis forming are most expensive at $150-300/hour. Laser cutting of reflective materials (copper, brass) costs 30-50% more than steel. Hand finishing and polishing can reach $100-200/hour for skilled labor.
9. Can I reduce costs by providing my own CAD files?
10. How does quantity affect per-part fabrication costs?
Per-part costs typically decrease by 40-60% when increasing from 1 to 100 units due to setup amortization. Further reductions of 15-25% occur from 100 to 1,000 units through process optimization. Volume discounts diminish beyond 5,000 units where material costs dominate.
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