When your job is sheet, not solid
CNC machining starts from a solid block and cuts material away. But a huge share of real-world parts — enclosures, brackets, panels, chassis, guards — start life as flat sheet metal that is cut, bent and joined. If that is your part, sheet-metal fabrication and laser cutting are usually faster and far cheaper than machining it from billet.
The core sheet-metal processes
Laser cutting
A focused laser cuts flat profiles from sheet with a clean edge and tight accuracy (around ±0.1mm), no tooling cost, and fast turnaround. Ideal for brackets, plates, gaskets, signage and any 2D profile. Fibre lasers cut steel, stainless and aluminium; thickness typically up to ~20–25mm depending on the machine and material.
Press braking (bending)
Once a flat blank is cut, a press brake folds it to shape. Bend radius, flange length and bend order all matter — and there are limits on how close a hole or feature can sit to a bend before it distorts. Design with generous bend reliefs and you will get a cheaper, more accurate part.
Punching & turret work
CNC punching is fast and economical for high-volume sheet parts with repeating holes and louvres, often combined with forming features (dimples, tabs, countersinks) in the same operation.
Welding & finishing
Folded and cut parts are welded, riveted or fastened into assemblies, then finished — powder coat, anodise, zinc plate or passivation. See the finishes guide.
Sheet metal vs CNC machining — which is cheaper?
| If your part is… | Best route |
|---|---|
| A flat profile, bracket or panel from sheet | Laser cut + press brake |
| An enclosure or chassis | Sheet metal (cut, bend, weld) |
| A solid block with pockets and bores | CNC machining |
| A precise mating/bearing component | CNC machining |
| Mixed (machined parts on a fabricated frame) | Both — fabricate the frame, machine the precision bits |
The rule of thumb: if the geometry is essentially "flat sheet, bent and joined", fabrication wins on cost and speed. If it is "solid with precise internal features", machine it. Many products need both — see milling vs turning for the machined side.
Designing sheet-metal parts well
Use a single material thickness throughout where you can. Keep bend radii consistent (one tool, fewer setups). Allow bend relief and keep holes away from bends. Avoid tiny tabs and slivers. Provide a flat DXF for laser profiles and a STEP for folded geometry — the CAD prep guide covers file formats.
Getting it made in Ireland
Several shops in our directory handle laser/router-cut flat work — CNC Ireland in Dublin runs combined laser- and router-head cutting on non-metal sheet, and the platforms (Protolabs Network, Geomiq) quote laser and sheet-metal alongside CNC. For metal fabrication, ask shops directly about laser capacity and press-brake tonnage when you brief them.
Frequently asked questions
Is laser cutting cheaper than CNC machining?
For flat sheet-metal parts — brackets, panels, profiles — laser cutting is usually much cheaper and faster than machining from solid, because there is no tooling cost and the cut is a single fast pass. For solid parts with internal features, CNC machining is the right route.
What thickness can a laser cut?
Fibre lasers commonly cut steel, stainless and aluminium up to roughly 20–25mm depending on the machine and material, with thinner gauges cutting fastest and cleanest.
Should I use sheet metal or CNC machining?
If your part is essentially flat sheet that is cut, bent and joined — like an enclosure or bracket — use sheet-metal fabrication. If it is a solid block with pockets, bores or precise mating surfaces, use CNC machining. Many products combine both.
What file format do I send for laser cutting?
A flat DXF is standard for 2D laser profiles; send a STEP file as well if the part is folded so the shop can see the 3D geometry and bend lines.
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