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All ServicesSHEET METAL FORMING AND TOOLING SERVICES
Custom forming of small metal components.
We have a wide experience in delivering metal forming on finished components for our customers. For over 55 years, we have been manufacturing bespoke parts with our in house design and toolmaking facilities. We pride ourselves on offering a complete service, which is why we offer forming on components, meaning that we can be your one stop shop supplier of metal parts. In addition to manufacturing your parts we are able to offer a variety of forming solutions to suit your individual needs. Whilst we typically work within prototyping and low volume production, we do have the expertise and equipment to offer competitive rates for higher volume forming production.
Send a component drawing of what you require and we will do the rest.
Types of tooling we offer are:
- Form Tools
- Blanking Tools
- Jigs and Fixture Tools
The benefits include:
- Quality components
- Repeatability
- Money saving
- Waste control
- Custom forming
- Volume
For more information on how we can reduce your costs & improve lead time contact our dedicated account managers on 01480 226699 or email enquiries@photofab.co.uk.
What is sheet metal forming?
Sheet metal forming or fabrication involves various processes where force is applied to a piece of sheet metal over a hard metal block or tool, to bend or shape the material, modifying its geometry rather than removing any material. Some of the common products created with our tooling and forming service are: PCB component housing, like RFI shields and fan covers, precision springs and electrical contacts, electronic connectors and metal clips.
Along with 100’s of stock universal tooling and capabilities for custom tooling, including custom multi-slide tooling for specialist radial forming. Our capabilities are backed up by a highly trained team and a multitude of presses. We have also invested in a new high impact press for forming thicker metals.
Typical components we etch and form
- EMI/RFI Screening cans
- Flat Springs
- Contacts
- Clips
- Earth Straps
- Brackets
Sheet metal forming and tooling options
Our metal forming department covers not only the bending of metal parts, soldering and spot welding, but also complex tooling manufacture using our in-house machinery to surface grind, mill and turn. We specialise in both prototyping and production runs.
Other types of formed components are available including half etch forming. The component will be drawn with a fold line in place and etched to half the thickness of the material, this can then be formed up into its desired shape either by hand or manual hand former. This is very useful for very low prototyping where applicable or EMI/RFI screening cans.
Half Etch Fold Lines
We are able to etch lines into a part. These lines are only etched halfway through the metal. By doing this, the metal can be formed.
- There is no form tooling charge
- Ideal for simple angle bends
- The parts can be formed in house by us
- You can form the parts on site yourselves
- Least accurate method of forming
- More generous tolerances are normally required
Uni-Tool
We have developed a “Uni-Tool”, which is an adaptable piece of hard tooling.
- There is no form tooling charge
- Low part price
- Fast turnaround
- Ideal for simple metal forming operations
- Good for prototypes
- Good for runs of up to 200 parts
- Good for accuracy.
Knife and Forking Prototypes
This is a hard tooling method, which uses several more complicated pieces of universal tooling and can cope better with more complicated parts.
- There is no form tooling charge
- Ideal for more intricate forming operations
- Good for prototypes
- Good for runs up to 200 parts
- Good for accuracy
Hard Form Tooling
Hard tooling to fit one of the fly or toggle presses is made, which can only be used on one particular part.
- This method incurs a form tooling charge
- Ideal for intricate forming operations
- Ideal for large quantities
- Very good for accuracy – generally to within +/- .1mm, subject to drawings
Screening Can Tooling
We have designed a series of tools which are adaptable pieces of hard tooling designed specifically for screening cans, while also providing low-cost options for spring fingered lids.
This is suitable for parts up to 200mm in length and width; however, the spring fingered legs need to be a minimum developed length of 3mm and rectangular for this method to be suitable.
Soldering and Spot Welding
We are able to solder and / or spot weld components, whether you require a seam soldered or two pieces spot welded together we can help.
General Tooling Services
We regularly provide precision surface grinding of metal, along with milling, turning, reaming, drilling and much more. If you have a need for a discipline not mentioned, please do contact us using the form below and ask.
Component Assembly
Our capabilities of assembling diverse components, allows customers to reduce their supply base using our logistical control team. We have a highly skilled team who will take your requirements, manufacture the components from raw materials, then assemble to your specifications.
Metals Suitable for metal forming
The foundation of the component is the metal.
We take great care in the selection of the right metal for the component application. Wherever possible, we use a special photo-etching grade, which is more uniform in thickness and flatter than normal stock. Our engineers and metallurgists will be pleased to advise on the grade of metal suitable for your application.
An extensive range of metals in various degrees of hardness and thickness are held in stock ready to meet a Rapid Delivery service. Metal thickness of 0.012 to 1.5 mm is suitable for through etching, and up to 6mm can be fabricated in-house.
The following list of metals is suitable for chemical etching and forming, and many are held in stock. If you don’t see what you need, please telephone us on 01480 226699 or contact us using the form below.
Stainless Steels
Austenitic (301, 302, 304, 316, S526, S527), Martensitic (321, 410, 420), Precipitation Hardened (17/7), Heat Resisting (309, 310)
Other Steels
Mild Steel, Carbon Steel, Tool Steel, Spring Steel, Transil, Losil.
Nickel Alloys
Nichrome, Mu Metal, Nickel Copper (70/30), Inconel, Nickel Brazing Foil.
Nickel/Iron Alloys
Invar, Alloy 42, Kovar, Radio Metal.
Copper
Tough Pitch 101, Oxygen free – High Conductivity.
Copper Alloys
Brass, Phosphor Bronze, Beryllium Copper, Nickel Silver, Ferry Constantan.
Aluminium and Aluminium Alloys
Silver and Alloys
Silver, Silver Alloys, Silver/Copper, Silver/Palladium, Silver Brazing Alloys.
To check the stock of particular metals, or advice on metal suitability, contact us or telephone on 01480 226699.
The benefits of
working with us
We are world leaders in the development of photochemical technology to produce intricately shaped components. We have produced over 80,000 different components over the years and are highly regarded for our chemical etching process. Our engineers offer many services that you can find here, and will offer advice to improve the product and reduce the costs.
24-hour quotation service
Dedicated account managers
Rapid manufacturing service
Cost saving stock of uni-tooling
Etched fold lines for tool-free forming
Full manufacturing service and supply chain management
Access to manufacturing and technical advice and expertise
Quality accredited to ISO 9001, ISO 14001, ISO 45001 and SC21 Bronze
The key difference
One of the key reasons we achieve high levels of customer retention and longevity is the team of dedicated account managers. This ‘single point of contact’ throughout the whole process, ensures a personal service, and pride in the quality and reliability of the entire service.
Customers rely on their dedicated contacts’ understanding and in-depth knowledge of their specific requirements and know the highest standards will always be met using the most efficient and cost-effective methods.
This consistent service is the foundation of our customer loyalty and is maintained throughout every department and every stage of production. Put us to the test for your next project and call one of our account managers on 01480 226699 or use our customer enquiry form.
Value added partnerships
We also have long working relationships with specialist partners for additional finishing services. These services can range from laser-cutting, plating, anodising and heat treatments which can add decorative finishes, prevent corrosion, and further improve durability.
All additional processes are managed closely and delivered with full transparency and traceability.
start your production journey today
If you are looking to find a complete service include dedicated engineering to design and implement your solution, get in touch with us. You’ll be given an account manager who is always on hand to advise and take care of everything for you. Call us on 01480 226699 or contact us now to see how we can add an extra dimension to your manufacturing project. Keep up to date by following us on LinkedIn.
TAKE A LOOK AT OTHER
SERVICES we offer
Chemical Milling / Chemical Etching
Since 1968, we have specialised in precision chemical etching, building a reputation as the world leaders through exceptional customer service, lead-times and quality management of chemical etching and value-added services.
Export
We understand the importance of reliable, high-quality manufacturing for businesses around the world. With an over 55-year legacy in supplying chemically etched components worldwide, our unique combination of versatility and unparalleled service makes us the ideal choice as your export partner. We believe in the power of international collaboration.
Dedicated Sheet Metal Engineering
We understand that engineering is an essential part of the production journey. That’s why we have heavily invested in a dedicated secondary engineering unit, with the aim of this is to offer an even greater service and flexibility to our customers.
Electronic File Handling
Digital files have now become an essential part of our tooling process – digital tooling gives a huge flexibility of design, while allowing our team to easily review and edit designs.
Metal Plating & Finishing
Photofab can offer a class-leading metal plating service, in a huge range of finishes. Metal plating is an important service that allows you to add certain properties, or a decorative finish, to your pieces. With a 24-hour turnaround time, Photofab is the perfect candidate to quickly fulfil the metal plating needs of your application.
Prototyping to High Volume
We offer our services in every possible volume – we can prototype single pieces and scale all the way up to a high-volume production. We offer this flexibility in a range of our industry leading processes.
Sheet Metal Forming & Tooling Manufacture
Our metal forming and tooling team have built a wealth of experience and expertise to compliment the established etching division and create a full manufacturing service.
Far East Supply Chain
We offer the option of utilising their strong relationship with a quality manufacturing supply chain in the Far East.
Laser Cutting
Our laser cutting service was created to offer customers precision cutting on materials thicker than 1.5mm whilst maintaining the same standards and quality control as our in-house etching services.
Metal Stamping
Metal stamping is best used for high volume applications, as the more volume is produced the better cost effective the initial outlay on the tooling is.
Photo Etching
There is a phrase often associated with our photo etching capabilities, “If you can draw it, we can make it”. With over 55 years experience and a large pool of technical knowledge, we are specialists in photo etching of thin metal parts.
To find out how we can help you
Get in touch today
