Tag Archive for: fabrication

How Laser Cutting Reduces Waste and Improves Efficiency

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In today’s world of manufacturing and fabrication, accuracy, speed, and material savings matter more than ever. Businesses are always looking for ways to cut down waste, save time, and get better results, and one of the most powerful solutions is laser cutting.

Laser cutting has quickly become one of the most preferred methods in industries that deal with metal, plastic, wood, and other materials. From creating detailed shapes to cutting large sheets with precision, laser cutting offers many benefits. In this article, we will explore how laser cutting helps reduce waste and improve efficiency in simple, clear words.

What is Laser Cutting?

Laser cutting is a process that uses a high-powered laser beam to cut materials into different shapes and sizes. The laser is focused onto a small point, and its heat is so intense that it melts, burns, or vaporises the material. This leaves behind a clean, sharp edge with little to no roughness.

Modern laser cutting machines are controlled by computers using CAD (Computer-Aided Design) software. This allows for perfect accuracy and complex designs that would be difficult to achieve with manual tools. Read in detail about laser cutting and its uses in manufacturing in our separate guide. 

Why Reducing Waste Matters in Manufacturing

Before we dive into how laser cutting helps, it’s important to understand why waste reduction is a big deal:

  • Saves money: Less waste means fewer raw materials are used, which lowers costs.
  • Protects the environment: Reducing material waste and energy use helps protect natural resources.
  • Improves productivity: When waste is low, processes run smoother and more parts are usable.
  • Better planning: Less waste leads to more accurate forecasting and purchasing.

A laser cutting machine operates, precisely cutting through a sheet of metal in a workshop setting.

How Laser Cutting Reduces Waste

Let’s look at some clear ways in which laser cutting helps cut down waste in manufacturing:

  • High Precision Cuts

Laser cutting is incredibly accurate. The laser beam can cut through materials with very fine tolerances, sometimes as small as 0.1 mm. This means that parts are cut exactly to the required shape and size, with little or no excess.

When you compare this to traditional cutting tools, like saws or shears, which can cause rough edges or wider cuts, you’ll see how much cleaner and tighter laser cutting is. Less material is removed, and less scrap is produced.

  • Optimised Material Usage with Nesting Software

Laser cutting machines often use nesting software, which arranges multiple parts on a sheet in the most efficient layout possible. It’s like solving a puzzle, fitting as many parts as possible onto a single piece of metal or wood with minimal space left over.

This smart planning reduces offcuts and leftover material that would otherwise go to waste. In factories that deal with thousands of cuts per day, this can lead to huge savings.

  • No Tool Wear = Consistent Results

In traditional cutting methods, tools like blades or punches wear out over time. As they get dull, they cause uneven cuts and waste more material. Laser cutting has no physical contact between the tool and the material, so there’s no tool wear.

This means every cut is just as good as the last one, which reduces errors, rejected parts, and material waste.

  • Minimal Setup Waste

Older machines often need test cuts or extra material to set up properly. This setup waste adds up over time, especially when starting new jobs. Laser cutters, especially CNC-controlled ones, need little to no test runs. Once the design is loaded, cutting can begin right away with high confidence.

This is great for custom projects and small-batch production where waste during setup can be costly.

  • Clean Edges = Less Rework

Laser cutting produces smooth, clean edges that usually don’t need extra work like grinding, sanding, or polishing. This means fewer damaged pieces, less scrap from rework, and fewer handling steps where material can be dropped or scratched.

Clean cuts also reduce the need for joints and welding, depending on the design, which further reduces material usage.

A laser cutter actively cuts a metal sheet, demonstrating precision in manufacturing.

How Laser Cutting Improves Efficiency

Reducing waste is only one part of the story. Laser cutting also boosts efficiency in several ways, making production faster, smoother, and more reliable.

  • Fast Cutting Speeds 

Laser machines can cut through materials very quickly, especially thin sheets. This speed reduces the time needed to complete a job, allowing more work to be done in less time.

In high-volume industries like automotive or electronics, every second counts. Faster cutting means more parts per shift and lower production costs.

  • Automation and Less Manual Labour with Laser Cutting

Laser cutters are usually controlled by computers and can run with little supervision. Many machines can even load and unload material automatically.

This reduces the need for manual labour, decreases human error, and allows workers to focus on other tasks. It also shortens training time because the machine does most of the work.

  • One Machine, Many Jobs

Laser cutters are versatile. They can cut, engrave, and mark many different materials such as:

  • Mild steel
  • Stainless steel
  • Aluminum
  • Plastics
  • Wood
  • Acrylic

Because one machine can handle so many jobs, there’s no need to change tools or machines for different materials. This saves time and space in the workshop.

  • Quick Change Between Designs

Switching from one design to another is simple. Just upload a new digital file, and the machine starts cutting immediately. This is a big time-saver for businesses that do custom orders, short runs, or prototype testing.

With traditional machines, changing dies or blades takes time. Laser cutting skips all of that.

  • Reduced Downtime

Since there are no mechanical parts touching the material, laser cutting machines need less maintenance. There’s less risk of damage, fewer moving parts to replace, and fewer production delays due to breakdowns.

Fewer problems = more uptime = more efficiency.

A laser cutting machine operates, precisely cutting through a sheet of metal

How Kirmell Uses Laser Cutting for Smart Production

At Kirmell Ltd, laser cutting is a key part of how we deliver accurate, high-quality metal components to our clients. Our modern laser cutting machines are used to cut mild steel, stainless steel, and aluminium parts with tight tolerances and smooth finishes.

By using CNC-assisted laser cutting and efficient nesting software, we make sure that materials are used wisely and waste is kept to a minimum. This helps our clients save on costs while still receiving parts that meet strict quality standards.

Whether it’s a one-off custom item or a large batch order, our laser cutting service ensures speed, precision, and minimal waste every time.

Conclusion

Laser cutting not only makes factories more productive, it also supports sustainability goals. With less waste, lower energy usage, and fewer reworks, manufacturers reduce their environmental impact while keeping quality high.

This is especially important as more companies aim for green certifications and eco-friendly production.

Looking for Expert Laser Cutting Services? Choose Kirmell Ltd

If you need fast, precise, and reliable laser cutting services, Kirmell Ltd is here to help. We provide custom laser cutting solutions for small to large projects, using high-end machines and expert staff.

Whether you’re cutting steel sheets for brackets or aluminium panels for enclosures, we ensure minimal waste and maximum efficiency. From design to delivery, your parts are made to exact standards on time and within budget.

Message us today at sales@kirmell.co.uk or fill out the form provided on the contact us page, and our expert will get in touch with you. 

FAQs 

 

How does an industrial laser cutting machine reduce waste?

An industrial laser cutting machine provides high-precision cuts with minimal material loss. Its accuracy means fewer mistakes and less scrap, helping manufacturers save money and use raw materials more efficiently.

 

Why is laser cutting important in the aerospace industry?

Laser cutting for the aerospace industry is essential because it ensures clean, accurate cuts on lightweight metals. This reduces the need for rework and helps maintain tight tolerances, key to building safe and efficient aircraft components.

 

What are the benefits of using an industrial metal laser cutting machine?

An industrial metal laser cutting machine offers fast cutting speeds, clean edges, and reduced setup time. It improves efficiency by minimizing manual labor and allows manufacturers to cut complex shapes quickly with less waste.

 

Can laser cutting machines work with multiple materials?

Yes. Modern laser cutting machines can handle various materials, including mild steel, stainless steel, aluminum, and more, making them ideal for multi-industry use, including aerospace, automotive, and electronics.

 

Does laser cutting help with energy efficiency in production?

Absolutely. Laser cutting requires less energy per cut compared to traditional mechanical cutting tools, especially for thinner materials, which adds to overall energy savings and eco-friendly production.

 

Advantages and Role of Fabrication in Manufacturing

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We live in a world built by manufacturing. From the cars we drive to the appliances in our homes and even the chairs we sit on, most of the things around us are made in factories. But before these products reach us, they go through many steps, one of which is fabrication.

Fabrication plays a very important role in turning raw materials, especially metal, into useful parts and products. It is used in almost every industry, and without it, modern life wouldn’t be the same.

In this article, we will explain in simple words what fabrication means, how it helps in manufacturing, and why it is so useful today.

What is Fabrication?

Fabrication means creating something from raw material. In manufacturing, this usually means taking flat metal sheets or metal bars and turning them into parts by cutting, shaping, bending, and joining them.

The main goal of fabrication is to produce parts that are ready to be used in a final product. These can be small items like nuts and bolts or large things like steel frames for buildings.

So, fabrication is not just one action; it is a complete process that includes many steps. These steps work together to create a finished, usable product. Read in detail about fabrication in our separate guide. 

a worker doing metal fabrication

Why is Fabrication Important in Manufacturing?

Fabrication is one of the most essential parts of the manufacturing process. Without it, industries wouldn’t be able to produce parts, components, or structures that are needed to build finished products. It not only brings product designs to life, but it also ensures that every piece is made to match real-world usage needs.

Let’s take a closer look at why it matters so much:

  • The Starting Point of Production

Before something can be assembled, its parts must be made. Fabrication is often the first physical step in production. It creates the metal parts that form the skeleton or structure of many products, from car bodies to shelves and industrial machinery.

  • Enables Complex Products

Modern products often include hundreds or even thousands of parts. Fabrication allows manufacturers to produce detailed and complex shapes that fit together perfectly. Whether it’s housing for electronics or structural components for a building, fabrication helps meet high design standards.

  • Essential for Custom Projects

Some businesses don’t need thousands of the same item they need custom parts built just for them. Fabrication is flexible enough to produce unique, small-batch items based on specific needs. This is very useful in industries like architecture, medical devices, or machinery, where no two projects are the same.

  • Reduces Dependency on Outsourced Parts

Companies that have in-house fabrication capabilities don’t have to rely on external suppliers for basic components. This gives them more control over quality, production speed, and costs. It also improves delivery timelines and reduces supply chain issues.

  • Supports Fast Prototyping and Product Testing

Before launching a new product, companies need to test and refine their ideas. Fabrication allows them to quickly build prototypes using real materials. This speeds up the product development process and helps catch design problems early.

  • Improves Product Strength and Safety

Fabricated metal parts are usually strong, durable, and long-lasting. They are capable of handling weight, stress, pressure, and other challenging conditions. This makes them ideal for high-performance environments such as automotive manufacturing, aerospace, construction, and transportation.

  • Critical in Almost Every Industry

From farming to furniture, and medical tools to mobile phones, fabricated parts are used everywhere. The versatility of fabrication means it fits the needs of multiple industries, making it a universal manufacturing solution.

Welder working in a factory, joining steel parts with a welding machine

Types of Fabrication Techniques

Fabrication is not just one single process. It includes a variety of methods that each serve a different purpose. These methods can be manual, semi-automated, or fully automated using machines and computer systems. Let’s explore the most common and important types of fabrication:

  • Cutting

Cutting is often the first step in fabrication. It involves taking a sheet, rod, or tube of metal and trimming it down to size. This can be done with basic tools like saws or with advanced machines like:

  • Laser cutters: For highly precise and smooth cuts
  • Plasma cutters: For thick metal sheets and heavy-duty jobs
    Water jet cutters: For materials that can’t handle heat

Each type of cutting is chosen based on the material type, thickness, and required finish.

  • Bending and Forming

This technique involves reshaping flat metal into angles, curves, or custom forms. It is done using press brakes, rollers, or hand tools. Forming is very important when creating brackets, frames, cabinets, or panels that must fit specific designs or sizes.

  • Welding

Welding is the process of joining two or more pieces of metal together by melting their edges and fusing them. It creates a very strong bond and is used in everything from car frames and structural beams to gates and furniture. Popular welding techniques include MIG welding, TIG welding, and spot welding.

  • Punching and Notching

Punching uses a machine to push a tool through the metal, creating holes or cutouts. Notching removes part of the metal at the edge or corner. These techniques are often used to make space for screws, bolts, switches, or wiring.

  • Shearing

This is a cutting method that works like a big pair of scissors. It’s used to cut straight lines through sheet metal without producing chips or shavings. Shearing is fast and clean, making it ideal for basic cuts before shaping.

  • Stamping and Presswork

Stamping uses a die and a press to form metal into a specific shape. This method is commonly used for making metal parts in large numbers. Items like car panels, electrical boxes, and appliance casings are often made using stamping.

A worker welds metal in a factory, wearing protective gear and a welding torch

  • Machining (CNC)

Machining involves removing material using tools like drills, lathes, or mills. When controlled by a computer, it’s called CNC machining (Computer Numerical Control). It’s ideal for producing very detailed and complex shapes with high precision.

  • Assembly and Finishing

Once all the pieces are ready, they are assembled into a final product using screws, bolts, welding, or adhesives. Then the product may be polished, painted, powder-coated, or treated to prevent rust and wear.

Each of these fabrication techniques can be used on its own or combined in different ways depending on the product’s needs. If you need more details, then check out this guide on Types of Metal Fabrication Processes

At Kirmell Ltd, we offer a wide range of fabrication services tailored to different industrial needs. From manual and CNC-assisted fabrication to welded assemblies and custom-made brackets or fixtures, our team handles everything in-house with precision and flexibility. 

We support both light and medium-duty fabrication projects, ensuring quality at every step and complying with ISO 9001:2015 and EN1090 standards. If you’re looking for a trusted fabrication partner for one-off jobs or ongoing production, get in touch with Kirmell today to discuss your requirements.

Real-World Applications of Fabrication

To better understand the role of fabrication, let’s look at how it’s used in different industries:

Construction

Fabrication is used to build staircases, steel beams, handrails, fences, and scaffolding. These parts must be strong and fit the exact design of the building.

Automotive

Car frames, doors, dashboards, and engine parts are all made using fabrication techniques. High precision and repeatability are essential to keep cars safe and efficient.

Electronics

Fabrication is used to build cases for laptops, servers, switches, and power supplies. These parts are lightweight, strong, and protect sensitive internal components.

Appliances

Fridges, ovens, washing machines, and microwaves all have fabricated metal parts like panels, trays, hinges, and supports.

Furniture

Modern metal furniture often uses fabricated frames, legs, and joints. These parts provide both function and design style.

Medical Equipment

Fabrication is used to produce surgical tools, hospital beds, and device enclosures. Clean finishes and accurate dimensions are especially important in this field.

At Kirmell Ltd, we regularly support clients in the medical, industrial, and commercial sectors by delivering reliable, project-ready fabricated components. Our experience with different fabrication methods allows us to meet high-quality standards while offering quick turnaround and tailored solutions.

A metal table in a metal shop, featuring a machine for fabrication and assembly tasks

Conclusion

Fabrication is more than just cutting or welding metal; it is a complete process that supports every stage of product creation. From simple parts to complex assemblies, fabrication plays a major role in modern manufacturing.

Its benefits, such as speed, accuracy, strength, flexibility, and affordability, make it one of the most useful and widely applied processes across industries. Whether you’re building cars, tools, electronics, or infrastructure, fabrication is the key that makes it all possible.

Looking For Fabrication Services? Reach Out to Kirmell

At Kirmell Ltd, we offer a complete range of fabrication services for industrial clients worldwide. Whether it’s a batch of small metal parts or a large-scale assembly, our team ensures every piece is made with care and precision.

We use the latest technology in laser cutting, CNC machining, presswork, and assembly to deliver parts that meet strict industry standards. Our experts work with clients during the early design stages, offering materials, prototyping, and full production support.

Looking for trusted fabrication support? Contact us at sales@kirmell.co.uk or fill out the contact us form, and we will get in touch with you. 

FAQs 

 

What is fabrication in manufacturing?

Fabrication is the process of turning raw metal into useful parts or products. It includes steps like cutting, bending, welding, and assembling to create items that can be used in machines, buildings, vehicles, and more.

 

Why is fabrication important in manufacturing?

Fabrication is important because it allows us to make strong and reliable parts from metal. These parts are used in almost every product we use daily, from kitchen sinks and car parts to steel structures in buildings.

 

What industries use fabrication?

Many industries rely on fabrication, including construction, automotive, furniture, electronics, medical equipment, and agriculture. Anywhere strong and precise metal parts are needed, fabrication plays a key role.

 

What materials are used in fabrication?

Fabrication uses many types of metal, such as steel, stainless steel, aluminium, brass, and copper. The type of metal used depends on the final product's requirements some must be strong, others lightweight or rust-resistant.

 

Does Kirmell offer fabrication services?

Yes! Kirmell Ltd offers a full range of metal fabrication services, including CNC-assisted fabrication, welded assemblies, and made-to-order metal components. We serve customers across the UK and EU and support projects of all sizes.

 

A metalworker grinds metal, producing a shower of sparks in the process

What is Metal Fabrication? A Beginner’s Guide

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Metal is a part of almost everything around us. Whether it’s the car you drive, the spoon you eat with, the building you live in, or the machines in factories, metal plays an important role. But metal doesn’t naturally come in the shapes we use. It has to go through a process to become useful, and that process is called metal fabrication. In this guide, we’ll explore what metal fabrication really means, how it works, and why it’s such a big deal in the world of manufacturing and construction.

Understanding Metal Fabrication in Simple Words

Metal fabrication is the process of turning raw metal materials into finished parts or products. This involves different steps like cutting, bending, joining, and shaping metal into the desired form. Think of it like baking a cake. You start with ingredients like flour, eggs, and sugar, and through mixing and baking, you turn them into a cake. In the same way, metal starts as sheets or rods, and through different processes, it becomes things like pipes, machine parts, railings, or even car frames.

This work is usually done in workshops or factories known as fabrication shops or metal fabrication facilities. Skilled workers, fabricators or metalworkers use machines and tools to cut and shape metal. Some of these processes are manual, but many use machines or computers for more precision.

At Kirmell Ltd, we offer a full range of fabrication services, including CNC machining, laser cutting, presswork, and welding. Our team works with clients across the UK and EU to deliver high-quality metal parts that meet industrial standards and tight production deadlines. Contact us now and get in touch with our expert if you are looking for industrial manufacturing services.   

welding process

Why is Metal Fabrication So Important?

Without metal fabrication, we would not be able to build many of the things that are essential to our daily lives. From simple tools like wrenches and kitchen knives to large structures like buildings, aeroplanes, and bridges, metal fabrication is what makes it all possible. It allows engineers and designers to bring their ideas to life by shaping metal in ways that suit different purposes.

Metal is strong and durable and can handle heat, pressure, and heavy loads. That’s why it’s used in many industries, including automotive, aerospace, construction, energy, agriculture, and even medicine. Imagine building a skyscraper or a ship without fabricated metal parts; it simply wouldn’t work. Metal fabrication gives us the power to build strong, long-lasting, and efficient products.

How the Metal Fabrication Process Works

Here is a detailed overview of the process of how metal fabrication works:

  • Design and Planning

Everything starts with a plan. Engineers or designers create technical drawings or digital blueprints of the product. These blueprints include the size, dimensions, shape, and materials required. Today, most of this is done using computer software like CAD (Computer-Aided Design) to ensure high precision.

  • Material Selection

Once the design is ready, the next step for sheet metal fabrication is choosing the right metal. The choice depends on the product’s purpose. For example, stainless steel is used for kitchen items, aluminium is used for lightweight parts like aeroplane components, and carbon steel is used for construction structures. 

  • Cutting the Metal

The raw metal comes in sheets, tubes, or bars, and it needs to be cut down to size. Cutting is done using tools like:

  • Laser cutters (for clean and precise cuts)
  • Plasma cutters (for thick metal sheets)
  • Shears or saws (for simpler cuts)
  • Waterjet cutters (when no heat should be applied)

Each method is chosen based on the type and thickness of the metal and the level of detail needed.

A worker preparing metal for welding in a factory

  • Forming and Shaping

After cutting, the metal is bent or shaped into the required form. Machines like press brakes apply pressure to fold or curve the metal. Rolling machines are used for cylinders or rounded items. Forming gives the metal its basic structure.

  • Welding and Assembling

The cut and shaped pieces are now joined together. The most common way is welding, which melts the edges of the metal and fuses them. Other joining methods include:

  • Riveting
  • Screwing or bolting
    Using adhesives (in lighter applications)

This step is where the product begins to take its final shape.

  • Finishing and Surface Treatment

The last step is making the product look good and perform better. Finishing can include:

  • Grinding to smooth the surface
  • Sandblasting to clean off any debris
  • Painting, powder coating, or polishing for appearance and rust protection

Sometimes, special coatings are added to make the product heat-resistant or water-repellent.

Real-Life Uses of Metal Fabrication

To better understand how common metal fabrication is, let’s look at some real-world examples. In the construction industry, metal fabrication is used to make steel beams, metal railings, doors, and windows. In the transportation industry, cars, buses, aeroplanes, and trains are full of metal parts made through fabrication, from the frame and engine parts to small components like brackets and panels.

In the world of appliances, items like refrigerators, ovens, and washing machines all use fabricated metal. Even medical tools, surgical scissors, hospital beds, and machines like X-rays have fabricated metal parts.

If you look around your home, you’ll probably find many items made through metal fabrication, like your kitchen sink, metal shelves, bed frames, or even decorative items like lampstands. It’s truly everywhere.

Saw cutting of a metal

Benefits of Metal Fabrication

Metal fabrication offers countless benefits, like:

  • High Strength and Durability

Metal parts made through fabrication are strong enough to handle extreme stress, heavy loads, and rough conditions. This is why metal is used in bridges, skyscrapers, vehicles, and tools that must last a long time.

  • Design Flexibility and Customisation

One of the best things about metallic fabrications is that they allow for custom designs. Need a one-of-a-kind machine part? No problem. With modern tools and machines, metal can be shaped into almost any form, making it easy to meet unique project needs.

  • Efficiency and Speed

Thanks to automation, CNC machines, and advanced cutting tools, metal parts can be fabricated quickly without compromising quality. This is especially useful when making large batches or meeting tight project deadlines.

  • Cost Effective for Large-Scale Production

While initial setup (like buying machines) might be costly, metal fabrication becomes very economical when producing items in bulk. Once the machines are programmed, they can create hundreds or thousands of identical parts quickly and accurately.

  • Recyclability and Sustainability

Most metals used in fabrication, such as steel, aluminium, and copper, can be recycled. This reduces waste, saves resources, and supports environmentally friendly manufacturing.

Its versatility makes it one of the most valuable processes in the modern industrial world. At Kirmell Ltd, we offer all key stages of the metal fabrication process, from precision presswork and component cutting to custom laser finishing, making us a trusted fabrication partner for the UK and EU industries. Read our brochure to learn more about our services and how we can help you. 

metal cutting using saw machine

Conclusion 

Metal fabrication may sound like a complex topic, but at its core, it’s simply about taking raw metal and turning it into something useful. Through cutting, bending, welding, and shaping, metal is transformed into products that help us live our modern lives, from cars and buildings to tools and appliances.

Understanding metal fabrication is important not just for engineers or manufacturers but for anyone curious about how the world around them is built. It’s a process that combines creativity, skill, and technology, and it’s all around us every day.

Looking for a Reliable Metal Fabrication Partner? Trust Kirmell Ltd

If you’re searching for a dependable metal fabrication partner to support your business, Kirmell Ltd is here to help. With decades of experience and a commitment to quality, we serve industries across the UK and EU with precision-engineered components and tailored fabrication services.

Whether you’re looking for a reliable supplier for batch components or help with a one-off development project, we have the expertise, equipment, and flexibility to support you.

Here’s what we offer:

  • Presswork: From medium to heavy-duty and deep-drawn pressings, we produce a wide variety of stamped parts using both traditional and CNC-assisted equipment.
  • Fabrication & Assembly: Our team handles welded assemblies and fabricated parts with rapid response capabilities and short-run flexibility.
  • Laser Cutting & CNC Machining: High-precision, cost-effective solutions for small or large volumes, suitable for industrial and engineering applications.
  • Component Development: We work with clients during early design stages and provide prototyping, material selection guidance, and tooling support.
  • Custom Products: We produce a wide range of items like pallet feet, nesting plugs, cubicle hardware, ladder standoffs, and more, all manufactured to ISO 9001:2015 and ISO EN1090 standards.

From rapid turnaround and flexible production to long-term supply partnerships, Kirmell is here to simplify your fabrication process and deliver components you can trust.

Ready to get started?

Visit our Contact Page and fill out the form provided to get in touch with our experts. 

FAQs 

 

What does a metal fabricator do?

A metal fabricator is someone who cuts, shapes, and joins metal to make useful parts or products. They use tools and machines to turn raw metal into things like frames, brackets, or gates. Metal fabricators follow drawings or designs to make sure each piece is the right size and shape.

 

What are examples of metal fabrication?

Metal fabrication is used to make many everyday items. Examples include car parts, metal doors, fences, kitchen sinks, shelves, and parts of machines. It also includes things like steel beams for buildings and pipes for plumbing. If it’s made from metal and has a shape, it likely came from metal fabrication.

 

Is metal fabrication done by hand or by machines?

Both! Some small or detailed work is done by hand using simple tools, but most modern metal fabrication is done with machines like laser cutters, press brakes, and welding machines. These machines help make parts faster and more accurately.

 

What materials are used in metal fabrication?

Common materials include steel, stainless steel, aluminium, copper, and brass. The choice depends on what the product will be used for. For example, stainless steel is great for kitchens because it doesn’t rust, while aluminium is light and good for cars or aircraft.

 

Can I get custom metal parts made?

Yes! at, Kirmell, we make custom parts based on your design or idea. Whether you need one special item or hundreds of the same part, custom fabrication can be done to fit your exact needs.

 

A factory worker performing welding duties

Different Types of Welding and How They’re Used

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Welding is one of the foundational processes in manufacturing and construction. Whether it’s the creation of skyscrapers, bridges, automobiles, pipelines, or even delicate medical devices, welding plays a crucial role in joining materials together. It involves melting the base materials, usually metals or thermoplastics, and often adding a filler material to form a strong joint once cooled.

Understanding the different types of welding processes is essential for selecting the right one based on the application, materials, strength requirements, cost, and precision needed. In this guide, we’ll explore the most common welding types, how they work, their pros and cons, and where they’re commonly used.

How Welding Works?

Welding works by applying heat, pressure, or both to fuse materials. The energy source can vary depending on the welding method. It might be an electric arc, gas flame, laser, electron beam, friction, or ultrasonic vibration. Here are the basic steps of most welding operations:

  • Preparation: The surfaces to be joined are cleaned and aligned.
  • Welding: Heat is applied to the materials using the selected welding method.
  • Filler Material (Optional): In many types of welding, a filler metal is added to strengthen the joint.
  • Cooling: The molten material cools down and solidifies, forming a strong bond.
  • Finishing: Excess weld material or slag is removed for a clean finish.

Each welding technique has different characteristics, advantages, limitations, and applications depending on the materials, thickness, position, and environment.

A worker welding two metal joint

Different Types of Welding

Here are the common types of welding used in industrial processes throughout the world:

1. MIG Welding (Metal Inert Gas Welding)

MIG welding is one of the most commonly used and versatile welding processes in both industrial and personal projects. Developed in the 1940s for welding non-ferrous materials like aluminium and magnesium, it has since evolved into a staple for welding steel and other metals. It is a type of arc welding that feeds a continuous solid wire electrode through a welding gun into the weld pool, joining the base materials together.

At Kirmell, MIG welding is widely used in the fabrication of mild steel and aluminium welding components due to its high efficiency, clean welds, and suitability for large-scale production. Our engineers rely on this method for fabricating structural frames, machine parts, and sheet metal products where consistent weld quality and speed are critical.

Looking for clean, efficient welding on your next project? Get in touch with Kirmell or explore our MIG capabilities through our brochure.

How It Works:

The welding gun continuously feeds a consumable wire electrode and releases an inert gas (usually argon or a mix with CO₂) to shield the weld area. When the arc forms between the electrode and the workpiece, both the base material and the wire melt to form the weld.

Common Uses:

  • Automotive manufacturing and bodywork
  • Furniture and metal fabrication
  • Home DIY projects
  • Sheet metal welding
Advantages Limitations
Easy to learn and operateLess suitable for outdoor use (wind affects shielding gas)
High welding speed and productivityNot ideal for thick materials
Produces clean welds with minimal slagRequires clean surfaces for quality welds

2. TIG Welding (Tungsten Inert Gas Welding)

TIG welding is considered the most precise and aesthetically refined welding process available. Developed in the 1940s to meet the aerospace industry’s need for strong, high-integrity welds on thin materials like aluminium and magnesium, TIG is now used anywhere high-quality, detailed welds are essential. It uses a non-consumable tungsten electrode and a separate filler rod (if required), all shielded by an inert gas like argon.

How It Works:

An electric arc is created between a tungsten electrode and the base metal. An inert shielding gas (typically argon) protects the weld area. The welder may manually feed filler material when needed.

Common Uses:

  • Aerospace components
  • Automotive exhaust systems
  • Stainless steel welding and non-ferrous metals like aluminium and magnesium
  • Artistic metalwork and piping
Advantages Limitations
Very clean and aesthetically pleasing welds
Slower process compared to MIG
Excellent for thin or delicate materials

Requires high skill and control
No spatter or slag
More expensive equipment setup

Welding process in a factory

3. Stick Welding (SMAW – Shielded Metal Arc Welding)

Stick welding is one of the oldest and most widely practised welding techniques globally. Its simplicity and ruggedness make it a top choice for heavy-duty applications, especially in outdoor or harsh environments. 

The welding equipment method used here consists of a consumable electrode coated in flux, which creates a gas shield and slag layer as it burns, protecting the molten weld from contamination.

SMAW is especially useful for welding thick materials like structural steel and is often used in shipbuilding, pipeline welding, and construction.

At Kirmell, we often utilise stick welding for structural steel projects, maintenance work, and on-site repairs where material conditions may not be ideal. This method allows our welders to work effectively even on rusty or painted surfaces, making it a reliable choice for fabricating heavy machinery frames and support beams.

Have a rugged job or on-site requirement? Get in touch with us and learn about durable solutions tailored to your industry.

How It Works:

An electric arc is formed between a flux-coated electrode (the “stick”) and the base material. The flux coating melts to create a protective gas shield and slag to cover the weld pool.

Common Uses:

  • Building construction
  • Shipbuilding
  • Pipeline welding
  • Heavy equipment repair
AdvantagesLimitations
Inexpensive and portable equipment
Generates slag that must be cleaned
Effective in windy and outdoor conditions
Less precise than MIG or TIG
Works on dirty or rusted materials
Not ideal for thin metals

4. Flux-Cored Arc Welding (FCAW)

The Flux-Cored Arc Welding is a variation of MIG welding but is designed for tougher conditions and heavier materials. It was developed as an alternative to shielded metal arc welding and combines the benefits of both MIG and Stick welding. FCAW uses a tubular wire filled with flux instead of a solid wire, allowing it to be used with or without a shielding gas, depending on the application.

This process is particularly favoured in construction, shipbuilding, and heavy equipment manufacturing due to its high deposition rates and deep weld penetration. Its ability to operate effectively outdoors and in windy conditions makes it more versatile than traditional MIG, especially when building or repairing large metal structures.

How It Works:

The flux core inside the wire creates shielding gases and slag as it burns. It can be self-shielding (no gas needed) or dual-shielding (additional gas used).

Common Uses:

  • Heavy steel construction
  • Structural beams and bridges
  • Shipbuilding
  • Outdoor fabrication
Advantages:
Limitations
High deposition rate
More spatter and slag than MIG
Effective for thick materials
Heavier equipment
Performs well outdoors
Not suitable for thin materials

metal welding process

5. Laser Beam Welding (LBW)

Laser Beam Welding is a precise, high-energy fusion welding technique that uses a focused laser beam to melt and join metals. It is especially valuable in industries that demand fine detail, minimal heat distortion, and high automation potential. The process produces narrow, deep welds with a very small heat-affected zone (HAZ), making it ideal for applications requiring tight tolerances.

Originally developed for aerospace and defence, laser welding is now common in the automotive industry for joining body panels and in electronics for delicate assemblies.

To understand more about how laser technology is revolutionizing material processing, check out our guide on What is Laser Cutting in Manufacturing: A Beginner’s Guide.

How It Works:

The laser generates intense heat, melting the joint area. It can be automated and used in environments requiring tight tolerances and low distortion.

Common Uses:

  • Automotive and aerospace sectors
  • Electronic components
  • Medical devices
  • High-precision metal parts
Advantages:
Limitations
High-speed, accurate welding
Very expensive
Minimal heat-affected zone
Requires a clean work surface
Clean finish and low distortion
Not suited for thick materials

6. Ultrasonic Welding

Ultrasonic welding is a solid-state process that uses high-frequency mechanical vibrations under moderate pressure to join materials, typically plastics and thin metals. The friction generated at the interface causes localised melting or softening, forming a strong bond without requiring heat input from an external source.

This method is widely used in industries where cleanliness, speed, and precision are paramount. In electronics, ultrasonic welding is used for wiring and microcircuit assembly. In medical device manufacturing, it is used to assemble plastic components without contaminating the product.

How It Works:

The materials are held together under pressure while ultrasonic vibrations are applied, creating heat through friction at the joint interface.

Common Uses:

  • Medical and electronic components
  • Toy and packaging industries
  • Wire harness assembly
  • Small plastic parts
AdvantagesLimitations
No need for solder or adhesives
Not suitable for large or thick parts
Fast and clean processLimited to thermoplastics and thin metals
Precise and controlled
Requires specialised equipment

Conclusion

Welding is a foundational process in manufacturing, construction, and design. From the robust and rugged stick welding to the fine-tuned precision of TIG and laser welding, each type offers specific benefits based on the materials, project requirements, and working conditions.

Kirmell’s Welding & Manufacturing Services

As a trusted UK-based precision manufacturer, Kirmell provides high-quality welding and fabrication services to support a wide range of industrial needs. Our facility is equipped to handle both light and heavy-duty projects across sectors such as construction, infrastructure, and machinery.

Our Welding Capabilities Include:

  • MIG and Stick welding for mild steel, stainless steel, and aluminium
  • Custom fabrication of frames, enclosures, panels, and support structures
  • CNC machining and laser cutting for tight-tolerance components
  • ISO 9001:2015 certified processes to ensure quality and consistency

Kirmell offers not only technical expertise but also a strategic location in the UK, giving EU clients a cost-effective and low-tariff alternative to outsourcing in Asia or the U.S., especially relevant in today’s volatile trade environment.

Need a trusted welding and supply chain partner in the UK? Partner with Kirmell today to strengthen your operations.

FAQs 

 

Which welding method is best for beginners?

MIG welding is generally considered the best option for beginners. It’s easy to learn, produces clean welds, and is ideal for light to medium metal fabrication like auto repairs, furniture, and DIY projects.

 

What is the safest welding process?

While all welding processes can be safe when proper precautions are taken, MIG welding is often considered one of the safest due to its ease of control and minimal open arc exposure. However, personal protective equipment (PPE) and good ventilation are essential for any welding type.

 

How hot is a welding arc?

A welding arc can reach temperatures between 6,000°C to 10,000°C (10,800°F to 18,000°F) depending on the method. This intense heat is what allows metals to melt and fuse together, so safety measures like arc shields and fire-resistant clothing are a must.

 

What types of welding services does Kirmell offer?

Kirmell offers MIG, TIG, and Stick welding as part of its full-service metal fabrication capabilities. These are suitable for steel, aluminium, and stainless steel projects ranging from structural frameworks to custom components.

 

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