Sheet Metal Fabrication Course

Lesson 1 • Sheet Metal Materials Overview

Covers common metals used in fabrication: steel, aluminium, copper, and stainless. Establishes material selection criteria central to all subsequent chapters.

Lesson 2 • Measurement and Layout Tools

Introduces rules, squares, scribers, dividers, and digital calipers for precise layout. Accurate measurement is prerequisite to every cutting and forming operation.

Lesson 3 • Reading Blueprints and Drawings

Teaches interpretation of orthographic views, dimensions, and tolerances on fabrication drawings. Blueprint literacy underpins accurate layout and cutting in later chapters.

Lesson 4 • Shop Equipment Identification

Surveys major machines: shears, brakes, rolls, and welders at an introductory level. Familiarity with equipment names and functions prepares students for hands-on chapters.

Lesson 1 • Pattern Allowances and Seam Design

Covers bend allowances, hem widths, and lap seam dimensions added to developed patterns. Correct allowances ensure parts assemble to final dimensions after forming.

Lesson 2 • Triangulation Development

Introduces triangulation for irregular transitions between rectangular and round openings. This advanced layout method handles shapes not solvable by parallel or radial methods.

Lesson 3 • Parallel Line Development

Uses parallel line method to develop patterns for prisms and cylinders. Students apply this technique to produce flat blanks that fold into correct three-dimensional shapes.

Lesson 4 • Geometric Construction Techniques

Applies compass, divider, and straightedge methods to construct angles, arcs, and bisectors. Geometric accuracy directly determines pattern quality in this chapter.

Lesson 1 • Cutting Quality and Edge Finishing

Addresses deburring, filing, and grinding cut edges to remove burrs and achieve dimensional accuracy. Clean edges are essential for safe handling and quality joint fit-up.

Lesson 2 • Power Shear Operation

Teaches setup, blade clearance adjustment, and safe operation of bench and foot-operated power shears. Shear operation produces straight cuts faster and more consistently than hand tools.

Lesson 3 • Nibblers and Throatless Shears

Introduces nibblers and throatless rotary shears for curved and irregular cuts without distortion. These tools extend cutting capability beyond straight-line shear limitations.

Lesson 4 • Plasma Arc Cutting Fundamentals

Covers plasma cutter setup, consumable selection, and hand-guided cutting technique on sheet metal. Plasma cutting enables fast, precise cuts on thicker gauges and complex profiles.

Lesson 1 • Box and Pan Brake Techniques

Applies the box and pan brake to form boxes, pans, and multi-bend parts with finger segments. Finger selection and sequencing determine whether complex parts can be formed.

Lesson 2 • Hand Bending and Folding Tools

Covers bar folders, hand seamers, and mallet techniques for forming flanges and hems manually. Hand tools develop tactile understanding of metal behaviour before machine work.

Lesson 3 • Roll Forming and Curving

Introduces slip rolls and plate rolls for forming cylinders, cones, and curved panels. Rolling complements brake bending for parts requiring continuous curvature.

Lesson 4 • Press Brake Setup and Operation

Teaches punch and die selection, back-gauge setup, and tonnage calculation for press brake bending. The press brake is the primary production bending machine in fabrication shops.

Lesson 1 • Riveting Techniques

Teaches solid and blind rivet installation, hole sizing, and rivet spacing for structural joints. Riveting provides permanent mechanical fastening without heat distortion.

Lesson 2 • Joint Design and Selection Criteria

Synthesizes seam, rivet, fastener, and adhesive options into a decision framework based on load, environment, and code requirements. Students select optimal joints for given applications.

Lesson 3 • Threaded Fasteners and Hardware

Covers screws, bolts, nuts, and clinch fasteners used in sheet metal assemblies. Threaded fasteners allow disassembly and are selected based on load and material thickness.

Lesson 4 • Hand-Formed Sheet Metal Seams

Covers grooved, Pittsburgh, and standing seams formed with hand tools and a groover. Seam selection affects joint strength, appearance, and airtightness in ductwork.

Lesson 1 • Heat and Distortion Control

Explains how heat input causes warping and teaches backstep, skip, and clamping strategies. Distortion control is the central challenge distinguishing sheet metal welding from structural welding.

Lesson 2 • Resistance Spot Welding

Covers electrode selection, pressure, current, and weld time settings for spot welding sheet steel. Spot welding joins overlapping sheets rapidly without filler material or visible seams.

Lesson 3 • TIG Welding Aluminium and Stainless

Teaches AC TIG for aluminium and DC TIG for stainless steel sheet, including filler rod selection. TIG provides the precision and cleanliness required for visible and food-grade surfaces.

Lesson 4 • Weld Inspection and Finishing

Addresses visual inspection criteria, grinding, and planishing to restore surface flatness after welding. Finished welds must meet both structural and cosmetic standards for professional work.

Lesson 1 • Surface Preparation Methods

Covers grinding, sanding, wire brushing, and chemical cleaning to achieve the surface profile required for coating adhesion. Preparation quality is the primary determinant of coating life.

Lesson 2 • Polishing and Brushed Finishes

Covers belt sanding, scotch-brite, and buffing techniques to achieve decorative brushed and mirror finishes. Decorative finishing is required for architectural, food-service, and consumer products.

Lesson 3 • Primers and Protective Coatings

Introduces epoxy, zinc-rich, and etch primers and their compatibility with topcoats. Primer selection is driven by substrate metal, service environment, and topcoat chemistry.

Lesson 4 • Spray Painting and Powder Coating

Teaches HVLP spray gun technique and powder coat application and cure cycles. Both processes deliver durable, uniform finishes on fabricated sheet metal parts.

Lesson 1 • Industry Standards and Codes

Introduces fabrication standards for ductwork, structural sheet metal, and pressure-containing parts. Awareness of applicable standards guides design decisions and inspection criteria.

Lesson 2 • Tolerance Analysis and Fit-Up

Teaches how individual part tolerances accumulate in assemblies and how to plan for fit-up. Tolerance stack-up analysis prevents costly rework during final assembly.

Lesson 3 • Weld and Joint Inspection Standards

Applies visual inspection criteria from recognised fabrication standards to welds and mechanical joints. Students identify and document nonconforming conditions for corrective action.

Lesson 4 • Quality Documentation and Traceability

Covers inspection records, material certifications, and traveller documents used in production shops. Traceability links finished parts to raw material and process records for accountability.