Advanced Sheet Metal Fabrication

Advanced sheet metal fabrication merges precision machinery with digital design and simulation.

Techniques for Complex Geometries

Modern engineering demands sheet metal components that are lighter, stronger, and geometrically more complex than ever before. From aerospace turbine shrouds and lightweight fuselage panels to architectural perforated facades, automotive structural reinforcements, and precision industrial enclosures, advanced fabrication sheet metal fabrication methods enable designers to push boundaries, achieving high precision, repeatability, and consistency even in intricate 3D forms, tight radius, and ultra thin materials (down to 0.5 mm).

At 77 Teknik, we combine CAD/CAM integration, digital simulation, and CNC technology to manufacture complex sheet metal parts that meet tight tolerances and functional requirements.

1. Digital Design & CAD Integration

Every successful fabrication project begins with a well prepared digital model. Using advanced CAD software, designers and engineers develop 3D parametric models that define every bend, hole, and cut with precision.

Key aspects include:

• Flattening complex geometries for accurate bend allowance calculations

• Applying DFM (Design for Manufacturability) checks to avoid distortion

• Automatically generating CAM data for cutting and bending

At 77 Teknik, the integration of CAD and CAM systems ensures seamless data transfer, reducing programming errors and improving production speed.

2. Precision Cutting: Laser, Waterjet, and Punching

Cutting is the foundation of any sheet metal process. Advanced facilities use multiple cutting technologies, each suited to different material types and tolerances:

• Fiber Laser Cutting: Delivers ultra fine edges and minimal heat distortion,  ideal for stainless steel and aluminum.

• Waterjet Cutting: Handles thicker or composite materials without thermal effects.

• CNC Punching: Efficient for repetitive hole patterns and mechanical forming (embossing, louvering).

Combining these technologies allows for flexibility in cost and precision , key in low  and high-volume production alike.

3. CNC Bending & Forming

Complex geometries often require multi-axis CNC press brakes capable of forming curves, angles, and folds with extreme accuracy.

Modern bending operations include:

• Automatic angle correction and springback compensation via sensors

• Robotic part handling for consistency and speed

• Offline simulation to predict tool interference and ensure manufacturability

77 Teknik utilizes simulation driven setups to minimize trial and error, achieving repeatable results even for intricate forms.

4. Assembly and Welding of Complex Structures

Once formed, components often require assembly into substructures using techniques such as:

• TIG and MIG welding for precision and structural strength

• Spot welding for thin-gauge metals in enclosure fabrication

• Riveting or bolting where disassembly is needed

• Adhesive bonding for composite-to-metal applications

Our team balances aesthetics, mechanical performance, and thermal control,  critical in architectural and defense grade assemblies.

5. Simulation, Inspection & Quality Control

Before production, digital forming simulations predict material flow and potential defects such as wrinkling or cracking. After fabrication, each component undergoes CMM inspection to verify geometry against CAD data.

At 77 Teknik, we maintain end to end traceability with:

• Automated inspection reports

• Surface and thickness analysis

• Tolerance verification aligned with ISO standards

This ensures every fabricated part performs exactly as designed,  both visually and structurally.

Advanced Sheet Metal Fabrication Tools & Methods at 77 Teknik

Tool / Method	Application
CAD/CAM Integration	Direct transfer from design to machine programming
CNC Laser Cutting	Precision shaping for complex geometries
Multi-Axis Bending	Forming non-linear and curved surfaces
Digital Simulation	Predicts deformation, springback, and stresses
CMM Inspection	Ensures dimensional accuracy and repeatability
Robotic Welding	Improves consistency and speed
Co-Engineering	Joint design optimization with customers

The Future of Sheet Metal Fabrication

The next evolution in sheet metal manufacturing lies in hybrid processes, integrating additive manufacturing, digital twins, and AI-driven quality prediction. By merging design data with real time machine feedback, manufacturers can achieve a closed loop system that continuously improves accuracy and efficiency.

At 77 Teknik, we invest in these technologies to provide smarter, faster, and more flexible fabrication solutions for industries ranging from automotive to defense and energy.

Turning Complex Designs into Precision Reality

Advanced sheet metal fabrication is no longer limited by material constraints or geometry.Through the integration of digital design, simulation, and high precision CNC forming, 77 Teknik transforms complex engineering concepts into manufacturable, high-performance parts.

Whether it’s a one-off prototype or a full production batch, our expertise ensures your components meet the highest standards of quality and precision.

Partner with 77 Teknik to solve with Advanced Sheet Metal Fabrication for Complex Geometries

From concept to production, 77 Teknik delivers precision, speed, and repeatability for even the most challenging sheet metal geometries.

Contact 77 Teknik to explore for  your next manufacturing project.