4 Common Metal Fabrication Mistakes

Metal fabrication requires precision, skill, and the right tools to achieve high-quality results. Whether working with an ironworker, hydraulic shears, or a press brake, our fabrication equipment builder wants you to be able to avoid falling prey to common mistakes so your business can save time, reduce waste, and improve overall efficiency. 

Here are 4 frequent mistakes fabricators make and how the right fabrication equipment can help prevent them.

1. Using the Wrong Metal Fabrication Equipment for the Job

One of the most significant mistakes in metal fabrication is selecting the wrong machine for a specific task. Every project has unique requirements, and using the wrong equipment can lead to material waste, poor-quality cuts, and even safety hazards.

A well-equipped shop should include a range of metal fabrication equipment, such as a hydraulic ironworker, press brakes, and a punch press, ensuring that every task is handled with the right tool. If you need assistance getting started and would like to discuss the demands of your industry, our trusted machine builder can provide expert recommendations on selecting equipment tailored to specific fabrication needs.

2. Incorrect Material Handling and Preparation

Even with high-quality metal fabrication machines, improper material handling can lead to costly errors. Before cutting, punching, or bending metal, it’s essential to ensure proper alignment and preparation.

A few common material handling mistakes include:

• Misalignment of metal sheets before processing, leading to inaccurate cuts or bends.
• Failing to deburr edges before running material through a hydraulic punch press, which can damage tooling and result in inconsistent punches.
• Neglecting to measure material thickness correctly before using a press brake, causing incorrect bending angles.

Investing in material handling solutions such as back gauges for press brakes, squaring arms for metal shears, and precision measuring tools can significantly improve accuracy and efficiency.

3. Overloading or Misusing Fabrication Equipment

Pushing fabrication equipment beyond its intended limits can result in excessive wear, machine failure, and unsafe working conditions. Operators often overload machines to complete jobs faster, but this can lead to premature breakdowns and costly downtime.

Signs of machine overloading include:

• Excessive strain or stalling when cutting thick materials with an ironworker machine or hydraulic shears.
• Using a press brake machine to bend material beyond its rated tonnage capacity, causing structural damage.
• Applying too much force to a punch press, leading to dull or broken tooling.

To prevent these issues, it’s crucial to follow manufacturer specifications and perform routine maintenance. Choosing high-quality, heavy-duty metal fabrication equipment from a reputable machine builder like ours ensures long-term reliability and performance.

4. Neglecting Regular Maintenance and Tooling Care

Even the most advanced metal fabrication machine requires regular maintenance to operate efficiently. Ignoring maintenance schedules can lead to reduced precision, safety hazards, and costly repairs.

Common maintenance mistakes include:

• Failing to lubricate moving parts on an ironworker machine, leading to excessive wear.
• Allowing metal debris to accumulate in metal shears, reducing cutting accuracy.
• Using dull punches in a hydraulic punch press, which can result in poor-quality holes and damage to workpieces.

Routine maintenance, such as cleaning, lubrication, and tool inspections, extends the lifespan of fabrication equipment and ensures optimal performance. Many modern fabrication equipment models come with built-in diagnostics and automated maintenance alerts to help operators stay on top of upkeep.

Avoid Mistakes With the Right Equipment

Part of preventing these common mistakes starts with investing in reliable, well-built machines like those from our metal fabrication equipment company. Whether it’s a hydraulic ironworker, press brake machine, or hydraulic shears, choosing the right tools improves precision, efficiency, and safety. Call Kalamazoo Metal Muncher today at (269) 492-0268 or contact us online to get started.