15 Metalworking Techniques Every Fabricator Should Know

In the world of metal fabrication, having the right tools is only half the battle—knowing the right fabrication techniques is what truly defines quality and precision. At Precision Bending, we use a wide array of forming, shaping, and joining methods to meet the exacting standards of industries like aerospace, automotive, energy, and custom manufacturing.

We created an overview of 15 key metalworking processes used to shape tubing, sheet metal, and structural components. Whether you’re sourcing a custom tube bending solution or trying to improve your manufacturing workflow, this guide provides insight into how each method contributes to performance and quality.

  1. Swaging: Swaging reshapes or reduces the diameter of a tube using high-pressure force and dies. It’s ideal for joining cables, tubes, or rods with fittings and is commonly used in hydraulic systems and mechanical assemblies.
  2. Flaring: Flaring involves expanding the end of a tube into a cone shape to fit with flared fittings. This ensures a leak-proof seal, especially important in fluid and gas transfer applications like HVAC or fuel systems.
  3. Coping: Coping is the process of contour-cutting the end of a tube to fit precisely against another tube or surface. It improves weld joint strength and is essential in structural and ornamental metalwork.
  4. Beading: Beading forms a raised ring or bead near the end of a tube. This improves structural rigidity and prevents hoses or clamps from slipping—crucial in automotive, plumbing, and industrial fluid systems.
  5. Drilling: Drilling creates precise, clean holes in metal for fasteners, vents, or fluid passage. Precision Bending uses CNC drilling systems to ensure consistent hole depth, diameter, and location across production runs.
  6. Flattening: Flattening compresses the end of a round or oval tube, creating a flat surface for welding, bolting, or mounting. It’s a practical technique for both structural components and custom brackets.
  7. Machining: Machining removes material to achieve specific geometries and tight tolerances. Our machining services include turning, boring, and facing, ideal for components that require exact fits or functional finishes.
  8. Milling: Milling uses rotating cutters to create slots, grooves, or complex surface patterns. With our multi-axis CNC milling, we can fabricate custom profiles for components in aerospace, robotics, and automation.
  9. Notching: Notching removes sections of material to allow for tight-fit joints or corner welds. It’s essential in frame construction, allowing for strong and visually clean assemblies.
  10. Piercing: Piercing pushes a punch through the metal without removing a slug, creating clean indentations or shapes. It’s fast and ideal for high-volume sheet metal fabrication where consistency is key.
  11. Punching: Punching removes a piece of material to create holes or cutouts. Using die-and-press systems, we offer custom punching services for brackets, panels, and enclosures.
  12. Slotting: Slotting creates long, narrow openings in metal for adjustability or mounting hardware. We handle slotting for both round and rectangular tubing, supporting everything from shelving systems to enclosures.
  13. Threading: Threading cuts or rolls helical grooves into a component, allowing bolts, nuts, or fasteners to securely attach. We provide internal and external precision threading for a variety of industries.
  14. Welding: Welding permanently fuses metal parts together. At Precision Bending, we offer TIG, MIG, and resistance welding, ensuring strength, durability, and visual appeal across different materials and thicknesses.

 Why These Metalworking Techniques Matter

Each process in this list serves a specific role in ensuring that fabricated parts meet structural, functional, and aesthetic requirements. Choosing the right combination of techniques can enhance product reliability, reduce assembly time, and even lower production costs.

At Precision Bending, we specialize in custom metal fabrication services that integrate many of these techniques under one roof—saving you time, improving accuracy, and streamlining your supply chain.

Ready to Bring Your Next Project a Reality?

Whether you’re developing a prototype or scaling up to production, Precision Bending can support your project with expert tube bending, swaging, welding, and more. Contact us speak with one of our fabrication specialists or request a quote.

Innovative Tube Assembly Integration: Combining Multiple Manufacturing Processes for Superior Performance

In the ever-evolving landscape of manufacturing, precision tube assemblies have emerged as a critical solution for engineers and designers seeking to develop component integration, reduce assembly complexity, and enhance product performance. Using fabricated tube assemblies in combination with metal stampings, machined parts, and castings, manufacturers can unlock new levels of design flexibility, structural integrity, and cost-effectiveness.

Strategic Advantage of Multi-Component Tube Assemblies

Modern manufacturing demands increasingly sophisticated approaches to component design and integration. Fabricated tube assemblies offer a versatile platform for seamlessly incorporating diverse manufacturing processes and materials. This approach allows engineers to leverage the unique strengths of different manufacturing techniques—each contributing its optimal characteristics to the final product.

The combination of the elements has different advantages. Metal stampings bring lightweight, high-volume production capabilities.  Machined parts provide precision and complex geometries. Castings contribute robust structural elements, and fabricated tubes act as the critical framework that binds these components into a cohesive, high-performance assembly.

Key Integration Techniques

Welding and Mechanical Fastening

Each technique offers unique advantages depending on material compatibility, structural requirements, and production volume. The most common methods of integrating different components into tube assemblies include:

  • Precision welding techniques such as TIG, MIG, and laser welding
  • Mechanical joining using specialized fasteners and mechanical interfaces
  • Brazing and soldering for creating metallurgical bonds between dissimilar materials

Design Considerations for Multi-Component Tube Assemblies

Successful integration requires careful consideration of several critical factors:

  1. Material Compatibility: Understanding the thermal and mechanical properties of different materials is crucial. Engineers must account for potential galvanic corrosion, differential thermal expansion, and mechanical stress during design.
  2. Tolerance Management: Precise dimensional control across different manufacturing processes ensures seamless component integration. Advanced metrology and statistical process control techniques are essential for maintaining tight tolerances.
  3. Weight Optimization: By strategically selecting materials and manufacturing processes, designers can create lightweight yet structurally robust assemblies that meet performance requirements while minimizing overall weight.

Industry Applications

Multi-component tube assemblies find critical applications across diverse sectors:

  • Automotive: Suspension systems, powertrain components
  • Appliances: Structural frames, hydraulic and pneumatic systems
  • Industrial machinery and heavy equipment: Robotic arm assemblies, material handling equipment

Economic and Performance Benefits

The integration of metal stampings, machined parts, and castings into fabricated tube assemblies offers significant advantages:

  • Reduced assembly complexity
  • Lower total component count
  • Improved structural integrity
  • Enhanced design flexibility
  • Potential for significant cost savings in high-volume production

Embracing a Holistic Approach

As manufacturing continues to evolve, the ability to effectively integrate diverse manufacturing processes will become increasingly important. Fabricated tube assemblies represent a powerful strategy for creating innovative, high-performance solutions that meet the demanding requirements of modern engineering.

By embracing a holistic approach to component design and leveraging the strengths of multiple manufacturing techniques, engineers can develop more efficient, reliable, and cost-effective products across virtually every industry.

Find out more about our fabricated tube assemblies and how Precision Bending can help your project.