Stainless steel light fitting support stirrups – connect metal
When designing sheet metal products if a part can be made from one piece of metal it will be the most effective design. Reducing the number of parts required, finished, inspected, assembled etc. will always be the cheapest solution. Obviously, this cannot always be the case. There maybe a situation where a component needs to have 2 different gauges or 2 different material properties. This then needs the designer to think about how they can connect metal.
Welding is a very versatile technique but not the only one. We can connect metal in several ways without having to melt anything.
Sheet metal work with pressed studs inserted
Mechanical and chemical joining methods are ones that can be used in everyday life. Many adhesives are now specially tailored to suit certain metal materials or operating conditions.
Cold solid riveting or pop riveting are both connecting methods that are quick and cheap. Again, they enable dissimilar materials to be joined together as well as different gauges.
Sheet metal projects with inserted bushes, studs, stand-offs, captive screws etc.
You can connect metal using self tapping screws. These have the advantage of speed. No need for threaded holes or masking if the sheet metal parts are being painting or powder coated. Little skill or equipment is needed in assembly. They do have the disadvantage of limited disassembly. Once a self-tapping screw had been used it’s not always possible to remove the screw and re-screw if servicing is needed. Then the best solution is a threaded (tapped) hole and a machine screw.
It could simply be that a machine screw with a tapped hole is sufficient to connect metal parts together. In very thin gauges this isn’t always possible, and a fixed male or female threaded insert can be used. Bushes, stand-offs and studs are very popular. We insert them in many thousands of metal parts for our customers.
There are various metal joining examples shown here with the photos of past projects. If you are not sure which method would be best, just send us your drawings and we will be happy to take a look for you.
For more examples of sheet metal projects please take a look at our Pinterest Boards