How to Approach Corner Construction for Custom Metal Fabrications (Updated for 2024)

Last updated on April 12th, 2024 at 07:51 am

When customers request a quote for sheet metal fabrications, they provide a flat design and we fabricate it into a 3D part. There are all sorts of considerations we take into account when we go from 2D to 3D.

Corner measurements are one of those quirks that we address on just about every part we make. Most of the time, the corners as designed will have a gap that needs to be welded closed.

It’s our job as your trusted sheet metal shop to ensure that your corners are strong, precise, and aesthetically pleasing-and we take that job very seriously.

Why Is Corner Construction So Important?

Not every shop is as obsessive about corner prep as we are. But when shops fail to prepare corners properly for welding, parts can end up out of tolerance, with weak and wavy corners that are prone to breakage. These issues are not in line with our quality standards. Your sheet metal fabrications need to stand the test of time without cracking under pressure.

Want to know how we guarantee high-quality corners every time? Take a look at our proven approach to corner construction.

Approved Sheet Metal’s Proven Approach to Corner Construction

Our approach to corner construction is largely dependent on part material. The heat from the welding process affects aluminum differently than steel or stainless steel, so these common sheet metal materials require different approaches:

• Aluminum. Aluminum parts call for open corner welds. Because aluminum isn’t as rigid as steel or stainless steel, it can’t stand up to heat in the same way. If we were to blast an aluminum part with too much heat, we could blow a hole in the material. So instead of risking that costly mishap, we rely on filler rods, which are just simple metal rods, to aid in the process. Filler rods help to reinforce and strengthen the corners. We melt them to the appropriate temperature before attaching them to the base of the part.
• Steel or stainless steel. With steel and stainless steel parts, we can perform a full outside weld. In this scenario, we only cut one side of the corner, so there is more material there than with aluminum, which means we need only a minimal amount of filler rod. Then, we fuse the metal together, creating a strong corner.

In addition to these approaches, we also leverage reliable techniques like interlocking tabs to strengthen corners and ensure beautiful welds every time.

Don’t let just any sheet metal shop construct your corners for you. Request a quote from Approved Sheet Metal and we promise we’ll never cut corners on cutting corners. 😉

Sheet Metal Part Design for Manufacturing Tip

CORNERS AND WELDING

Proper technique on corners that need to be welded is necessary to reduce cost and increase the overall strength of the corners. Approved Sheet Metal will always reprogram corners that need to be welded to ensure customers receive the best possible welds.

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Metal Fabrication Corner Construction FAQ

Why is proper corner construction crucial in sheet metal fabrications?

Corner construction plays a vital role in ensuring the durability and strength of sheet metal parts. When corners are not properly prepared for welding, it can lead to parts being out of tolerance, weak, and susceptible to breakage. Our obsessive attention to corner prep ensures that your fabricated parts meet high-quality standards and can withstand the test of time without compromising under pressure.

How does Approved Sheet Metal ensure high-quality corners in every fabrication?

Our approach to corner construction varies based on the material of the part. For aluminum parts, we utilize open corner welds due to aluminum’s sensitivity to excessive heat. To avoid damaging the material, we use filler rods to reinforce and strengthen corners, ensuring a solid weld without compromising the integrity of the aluminum. In the case of steel or stainless steel parts, we perform full outside welds, using minimal filler rod to fuse the metal together and create robust corners.

Why do aluminum parts require a different corner construction approach?

Aluminum is less rigid than steel or stainless steel, making it sensitive to high levels of heat during the welding process. To prevent the risk of blowing a hole in the material, we employ open corner welds with filler rods. These filler rods reinforce the corners and provide the necessary strength while avoiding excessive heat exposure.

How do you handle corner construction for steel and stainless steel parts?

For steel and stainless steel parts, we perform full outside welds. This involves cutting only one side of the corner, leaving more material compared to aluminum. With the addition of a minimal amount of filler rod, we fuse the metal together to create strong corners. This approach is effective in maintaining the structural integrity of the parts while ensuring aesthetically pleasing welds.

Are there additional techniques you use to enhance corner strength and weld aesthetics?

Yes, in addition to the corner construction approaches mentioned, we also implement reliable techniques like interlocking tabs. These tabs further strengthen corners and contribute to achieving beautiful welds consistently. Our commitment to detail and precision ensures that every aspect of corner construction is optimized for the best possible results in your sheet metal fabrications.