The Art and Beauty of Metal Fabrication
Being a custom metal fabricator is one of the most exciting and rewarding undertakings one can be involved in. It means being a critical part of so many industries—providing creative solutions to companies ranging from mining to construction, and oil to architecture.
As a fabricator, we get to work with leaders in their field and true American innovators. It also means working with some of the most creative and talented people in the world, and having the opportunity to be creative in the process.
For instance, we recently had the chance to work with an artist, helping to design a beautiful sculpture that is now prominently on display near the United Center in Chicago.
This artist came to us with a vision for the sculpture. They provided drawings and CAD files, and we worked closely with them to create a design plan: to plasma cut two separate plates on our large plasma table and weld them together into one large fabrication.
The torch came down and cut out areas of the metal piece, cutting specifically to the project’s design, in one-inch-thick carbon steel. Two panels were created, each panel measuring 10 feet tall and eight feet wide. We then welded the fabrication and upon final inspection and approval, it was sent to be painted and installed.
In the end, the result was a beautiful metal sculpture that matched the initial design and was expertly made and crafted, whose aesthetics matched its quality. It serves as a great example of work that is not only the epitome of fine metal workmanship, but also a piece of art—something that can be enjoyed for generations.
We love having the opportunity to make our work enjoyable to so many others and making an artistic dream a reality.
Manufacturing Top-Quality Long Parts
Here at G.E. Mathis Company, we pride ourselves on the ability to manufacture a wide range of high-quality components of all shapes and sizes. By staying informed about the latest and greatest manufacturing equipment and processes, we can stay ahead of the competition and do what other manufacturers cannot. One area in which we excel is the fabrication of long parts. This is something that many manufacturers are not capable of doing; our equipment and capabilities offer us a distinct advantage in this market segment.
When making long parts, some manufacturers, due to equipment limitations, may have to fabricate short pieces first. If you want a piece that’s 30 feet long and a manufacturer can only fabricate pieces that are 10 feet long, they would need to form that long part by welding together three different pieces. The problem is that all three of these pieces may not come out exactly the same, leading to the fabrication of a long part with flaws that could greatly lower the quality of the piece.
On the other hand, we’re able to form longer components in just one piece. This is thanks to our lineup of eight precision press brakes that can easily handle lengths of 20 to 48 feet. This means that the customer gets a higher-quality, more consistent part in one piece to the length. The whole long part is completely uniform and our manufacturing process eliminates the middle seam in a formed piece, which allows us to cut down on secondary processes that cost more time and money.
So when you need uniform, high-quality long parts, come to the experts. We can make all sorts of long parts, like angles, channels, bump formed segments, and cone segments, and we have experience working with a wide range of materials, from carbon, stainless steel, and aluminum, as well as alloy steel.
Custom Manufacturing: Our Process
Custom manufacturing: It is what our business is built on and is what our customers know us best for. However, how familiar are you with the custom manufacturing process? In other words, are you aware of how fabricators like us actually produce your desired parts?
Design and Quote
Typically, our process begins when a customer approaches us with a drawing of the specified parts or components with the requirements and features precisely detailed. Although we don’t design and engineer a part, we can work with a provided drawing and determine whether or not the specifications will work with our capabilities. At this point, we will provide the customer with a quote, detailing the materials and processes we will be utilizing, as well as the lead time for delivery of parts for the customer to determine whether this will fit into their schedule.
Fabrication
Once a part’s design is set and the quote is approved, it’s time for the fabrication process to begin. Each part will have necessary steps that need to be followed by our engineers. If the part is flat plate or a piece with geometry, then it can be programmed and cut. However, if the part has a more complicated design, then there are more steps in the fabrication, thus extending the process’ time frame.
Throughout the whole process, we maintain consistent communication with our customers, ensuring the part is completed correctly from the beginning stages to the final product. We work diligently to ensure the parts are fabricated to the highest quality and reach their end point right on time. It is our goal to give our customers exactly what they want and need—we have made sure our custom manufacturing process does just that.
Choosing the Right Material for Your Fabrication Needs
During the initial planning phase of fabrication, there are many things to consider. One of the most important of these considerations is material selection—what’s the absolute best choice for your part?
In industries and applications where the metal will be coming into contact with other hard materials that can wear it out due to abrasion, a good choice is an abrasion resistant (AR) plate. AR plates are designed for use in harsh environments.
Of course, there’s more than one type of AR plate. We recommend using HARDOX® Wearplate, which is chemically engineered to provide abrasion resistance throughout the entire thickness of the material, not just the surface. Many other AR plates only offer the abrasion resistance on the surfaces of the material, becoming softer towards the center of the material. Specific benefits of HARDOX® Wearplate include:
HARDOX® Wearplate is generally more formable.- Readily weldable without pre- or post- heating (whereas pre- and post-heat may be necessary to prevent stress fractures in the material and the weld itself when using regular AR plates, no heat treatment is needed for HARDOX® Wearplate up to 2 inches).
- Longer part life as a result of even abrasion resistance throughout the thickness of the plate.
- HARDOX® Wearplate is blasted and primer coated at the mill, which results in material that better resists rusting and scaling.
HARDOX® Wearplate is generally more formable.While different machining processes and specific environments can affect material choice, as a general rule, when an AR plate is right for the job, HARDOX® Wearplate can be highly advantageous. In mining, construction, and other industries, it’s been known to save time, money, and worry. As an official HARDOX® Wearparts member, (one of only a handful in the country audited and authorized by SSAB, the maker of HARDOX® Wearplate), G.E. Mathis Company has a great deal of experience using it, and therefore is well aware of its benefits. When selecting abrasion-resistant material, put your confidence in a fabricator with a proven track record.
