How Is Custom Sheet Metal Fabrication Important for HVAC?


In the last few decades, HVAC systems became more of a necessity than a luxury. They truly make your home a lot more comfortable as the temperature is adjusted to your needs! However, HVAC systems contain numerous components, and all of them work together to provide you the desired temperature.

One of these components is intricate ductworks, which are commonly made of metal sheets. They are responsible for distributing the hot or cold air evenly in every area. In this article, we will talk about using sheet metal fabrication for an HVAC system, the basics, advantages, and disadvantages. Stick around for more information.

In case you are looking for a complete HVAC solution, do visit professionals like Anderson Air.

What is Sheet Metal?

Fabricated sheet metal is the most commonly used material for HVAC ductworks. It replaced polyurethane and fiberglass due to its flexibility. It can be custom-made to suit the requirements of each system.

The materials used are:

  • Aluminum
  • Steel
  • Copper
  • Brass
  • Magnesium
  • Bronze

These materials are very adjustable as they end up being thin pieces of metal that can be shaped in different forms. However, the two most popular materials out of these six are:

Galvanized Mild Steel

This is the most commonly used material for building ductworks. It prevents corrosion and does not allow for rust buildup. The material is flexible and can fit the shape of any installation. Such ducts are fabricated using duct wraps that help prevent noise, leakage, and hot or cold air loss.


This is another commonly used material since it is lightweight and highly flexible. Aluminum sheets have pre-insulated panels, cut into particular shapes and sizes and then put together using tape or glue.

What is Sheet Metal Fabrication?

Sheet metal fabrication involves getting an HVAC system tailored to your needs. The sheets are custom-made to suit your current ductwork. This might be a lengthy process, but in the long run, it will prove beneficial.

Poorly designed ductworks can lose around 30% of the air due to different leaks. This is why custom sheet metal fabrication is very useful!

The fabrication process has three main components:


When you take a large sheet of galvanized metal, there are several things that you need to do with it. The first thing you want to do is to measure and mark the pieces based on your needs. Once this is done, the sheets are ready for cutting.

This is done using various tools and is also called shearing, as the pressure causes metal to shear. CNC machines are often used for precise cuts, but fabricators also use metal cutters, saws, chisels, and torches.


After the metal is cut into pieces, it is time to mold them into a particular shape. They are shaped depending on the placement and the shape that will suit a more extensive system. This is done using machines and hand tools.

Some of the machines used for this process are folding, notching, flange forming, pneumatic corner mounting, etc. Regardless of the machine used, there must be enough pressure to bend and shape the metal!


After the pieces have been cut and shaped, it makes sense to put them together! It is crucial that this process is conducted with utmost care. Improper assembly can cause several long-term issues with the system.

The pieces can be welded together or connected using threaded fasteners, rivets, powerful adhesives, etc.

Once this is done, fabricators often apply a durable powder coat treatment as a finishing part!

Benefits of Sheet Metal Fabrication

Custom sheet metal fabrication can be incredibly useful! Some of its main benefits are the following:


The primary function of using sheet metal fabrication is to prevent leakage. This saves you a lot of money on repairs, and the system will use up less energy, causing your bills to be lower.

Using such ducts reduces the chances of breakdowns and rust, making the system more durable. This means that you will not have to replace the parts often, making this a wise long-term investment.

Fits Your Current Project

Whether you want to remodel the system you currently have or build a new structure, this is easily done using sheet metal fabrication!

The pieces are customized on a computer to fit your project perfectly. The machines will manufacture them according to your needs and specifications. The process does not generate a lot of waste, making it an environmentally conscious approach.

Makes Your Home More Comfortable

Sheet metal fabrication does not only make sure that you get all of the filtered air, but it also ensures insulation and no noise! You will get all of the benefits without experiencing inconveniences all the time. Enjoy the comfort of your own home!

Setbacks of Sheet Metal Fabrication

Even though custom sheet metal fabrication is generally more beneficial than not, it is only fair to mention that it has some setbacks, as well.


The forming process might take quite some time. In some cases, you might have to wait a bit longer for everything to be done. That also means that it will cost you money to pay for the time spent working on this.

However, this also depends on the kind of process. Not every project requires the same amount of effort. Sometimes the process is manual, whereas other times, the machines do most of the work.

Viscous Metal Is Not As Flexible

Metal fabrication, in general, gives you a lot of flexibility. However, if you are using molten or viscous metal, you might not be able to get advanced shapes and designs.


Sheet metal fabrication has proven itself efficient and money-saving! The process consists of a couple of components, but the main goal is to prevent leaks, keep the conditioned air inside, and have a flexible system that can be adjusted when needed!

Consider consulting professionals before making a decision. They would be able to provide you with suitable suggestions and alternatives.



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