Sheet Metal
Fabrication Services
20 Power Presses. 3000W Fiber Laser. 7 Tank Powder Coat. Complete sheet metal fabrication process cutting, forming, welding, and finishing under one roof at Vasai.
ISO 9001:2015 · Vasai, Mumbai, Maharashtra, India
Complete Sheet Metal Fabrication Services in Vasai Mumbai
Aero Enterprises is one of the integrated sheet metal fabrication companies in Mumbai operating a complete sheet metal workshop at Unit I Vasai Phata - covering every stage of the sheet metal fabrication process from material sourcing to finished powder-coated components. Our sheet metal fabrication covers the full fabrication process: laser cutting, blanking, piercing, punching, notching, bending, deep drawing, welding, and powder coating - no subcontracting, no vendor handoffs.
As a complete sheet metal fabrication partner for OEM manufacturers, we handle all types of sheet metal operations - from sheet metal stamping process on 20 power presses to precision sheet metal bending calculation-backed CNC bending and shearing process in sheet metal on our 10-machine shearing division. Serving LED lighting, automotive, solar tracker, furniture, and stationery OEMs from our sheet metal workshop at Vasai since 2014.
What We Do
Sheet Metal Fabrication Capabilities
One-Stop Sheet Metal Fabrication - Mill-Certified Sourcing to Surface Finishing
Power Press Stamping
"Sheet metal stamping and sheet metal stamping process across 20 hydraulic and mechanical presses from 10T to 150T. Progressive, compound, and deep draw dies for LED lighting, automotive, tracker OEM, furniture, and stationery component production. Punching operation in sheet metal, piercing in sheet metal, sheet metal blanking, and deep drawing sheet metal - all in-house on our sheet metal punching machine range."
- 20 Power Presses - 10T to 150T Range
- Progressive, Compound and Deep Draw Dies
- Sheet Metal Stamping Process to ±0.2mm
CNC Multi-Axis Bending
"CNC press brake 100T / 3100mm with multi-axis back gauge for precise bending operation in sheet metal to ±0.5°. Sheet metal folding and complex profile forming across MS, SS, GI, aluminium, brass, and copper. Minimum bend radius sheet metal compliance verified per material grade. Sheet metal bending tools include CNC, manual press brakes, and power press form bending."
- ±0.5° Angle Repeatability Performance
- 3100mm Bed - CNC, Manual and Press Layouts
- Minimum Bend Radius Verified Per Material Grade
Industrial Powder Coating
"7-tank chemical pre-treatment, two electrostatic spray booths, and three thermostatically controlled curing ovens up to 4x10x10 ft with crane operation. Handles sheet metal enclosure finishing, sheet metal box coating, structural assemblies, and fabricated frames requiring consistent Class 5B adhesion across multi-batch OEM runs."
- 7-Tank Chemical Pre-Treatment Line
- 3 Ovens including Crane-Operated 4x10x10ft Layout
- Class 5B Adhesion for Enclosures and Boxes
Fiber Laser Cutting
"3000W CNC sheet metal laser cutting machine on a 1500x3000mm bed. Cuts MS up to 20mm, SS, GI, aluminium, brass, and copper with nitrogen and oxygen dual assist gas. CAD/CAM nesting for sheet metal laser cutting designs optimization - oxide-free cutting edges for downstream forming and welding operations."
- 3000W Sheet Metal Laser Cutting Infrastructure
- Laser Cutting Designs via CAD/CAM Nesting Cuttings
- Nitrogen and Oxygen Assist with ±0.1mm Tolerances
Shearing, Blanking & Secondary Ops
"Shearing process in sheet metal using CNC shearing, hydraulic shearing, and manual sheet metal shear machines. Kachi light-gauge cutting for 0.5mm sheet metal below 1.5mm - analogous to sheet metal cutting scissors for fine gauge work. Sheet metal blanking for flat-profile preparation, drill tapping M3-M16, and surface grinding at Unit I."
- Shearing Process via CNC, Hydraulic and Manual Shear Systems
- 0.5mm Sheet Metal Kachi Light-Gauge Processing
- Sheet Metal Blanking and Thread Tapping M3-M16
Certified Welding
"6-machine welding division running MIG, TIG, and ARC on MS, SS, GI, aluminium, brass, and copper, plus two resistance spot welders. Sheet metal machining and secondary operations - grinding and vibratory deburring - performed on all weld assemblies before surface finishing. ASME and ISO compliant WPS documentation."
- MIG, TIG, ARC and Spot Configurations - 6 System Units
- Sheet Metal Machining including Deburr and Grind Refining
- ASME and ISO Compliant WPS Document Control Validation
Sheet Metal Technical Consultation
"36 years of floor-level knowledge covering material grade selection, DFM review, sheet metal defects root-cause analysis, nesting yield, MTC verification, and fabrication process sequencing. Provide your sheet metal part drawing or sheet metal design drawings - we return a full DFM review, sheet metal defects risk assessment, and fabrication process recommendation."
- ISO 9001:2015 Certified Engineering Oversight
- Sheet Metal Defects and Structural Failure Structural Analysis
- Sheet Metal Part Drawing DFM Engineering Reviews
Technical Reference
Types of Sheet Metal Operations
The sheet metal fabrication process is built from a set of core sheet metal operations - each serving a distinct purpose in the fabrication process. There are two primary categories: cutting operations (blanking, piercing, punching, notching, shearing) and forming operations (bending, deep drawing, embossing, beading). Understanding types of sheet metal operations helps OEM engineers specify the right process for each feature - and Aero Enterprises performs all 8 in-house at our Vasai sheet metal workshop. See a complete breakdown with definitions, sheet metal operations with diagrams-style descriptions, and machine specs below.
Blanking
Sheet metal blanking punches a complete flat shape from the parent sheet - the punched piece is the required blank. Used for consistent flat-profile preparation before any forming operation.
Piercing
Piercing in sheet metal cuts holes through the blank - the punched-out slug is waste. Piercing operation in sheet metal is performed simultaneously with blanking in compound dies for efficiency.
Punching
Punching operation in sheet metal removes material to create holes, slots, or notches. Punching process in sheet metal uses a punch and die set on our 10T-150T sheet metal punching machine range.
Notching
Notching in sheet metal removes corner or edge material to allow clean sheet metal folding and bending without material collision - critical for sheet metal box and enclosure corner joints.
Bending / Folding
Bending operation in sheet metal forms angular profiles. Sheet metal folding on CNC press brake to ±0.5°. Types of sheet metal bends produced: air bending, bottoming, coining, V-bending, and wipe bending.
Deep Drawing
Deep drawing sheet metal forms flat blanks into cups, boxes, and enclosures. Drawing operation in sheet metal used for LED housing shells, driver compartment bodies, and deep-drawn enclosure components.
Embossing
Sheet metal embossing creates raised or recessed features. Embossing operation in sheet metal and embossing process in sheet metal are used for stiffening ribs, identification marks, and surface texture.
Beading
Beading in sheet metal forms a rounded bead or rib along the surface to increase rigidity without adding thickness. Common in sheet metal enclosure, panel, and frame stiffening applications.
Sheet Metal Fabrication Process - End to End Workflow Routing
CNC Bending Technical Reference
Sheet Metal Bending - Calculation, Formula & Bend Allowance
Sheet metal bending calculation determines the correct flat blank length before bending. The standard sheet metal bending formula uses Bend Allowance (BA) - the arc length of the neutral axis through the bent zone. Correct sheet metal bending calculation prevents under-sized or over-sized blanks that cause assembly failures. Our engineers verify minimum bend radius sheet metal compliance per material grade before every CNC job.
What is Bend Allowance in Sheet Metal?
Bend Allowance (BA) is the length of the neutral axis arc through the bend zone. It must be added to the flat blank dimensions to get the correct developed length. What is bend allowance in sheet metal? - it compensates for material stretching at the outer bend radius.
Sheet Metal Bending Formula
BA = A × (π ÷ 180) × (R + K × T)
A = Bend angle (degrees) | R = Inside bend radius (mm)
K = K-factor (0.33 to 0.50) | T = Material thickness (mm)
K-factor range: 0.33 (sharp bend) → 0.50 (neutral axis centred)
Sheet Metal Bending Tools Available
- CNC Press Brake 100T / 3100mm - Primary bending tool
- Manual Press Brake 6.5ft x 2 - Secondary folding
- Power Press Form Bending - 20-press floor
- 3-Roll Bender - Large-radius profiles
- V-Die Set Inventory - Multiple angles and radii
Types of Sheet Metal Bends
Air Bending
Punch contacts material, die provides clearance. Springback must be compensated. Most common CNC press brake operation - used for most standard angle bends across all sheet metal grades.
Bottoming
Punch presses material fully to die bottom. More accurate than air bending with reduced springback. Standard sheet metal bending tool setup for tight tolerance work.
Coining
Maximum tonnage - material flows into die cavity. Highest accuracy, least springback. Used for precision sheet metal bending where final angle accuracy is critical.
V-Bending
Most standard CNC press brake setup. V-die and punch. Applied across all material grades and thickness ranges in sheet metal folding and bending operations.
Wipe Bending
Material is wiped over die edge. Fast for simple flanges and sheet metal folding on thin gauge 0.5mm-1.5mm material where speed matters.
Roll Bending
Used for large-radius bends and curves on structural channels - sheet metal bending tools include a 3-roll bender for architectural and structural profiles.
From Coil to
Components
JSW and TATA certified coils enter at Unit II Dhumal Nagar and finished powder-coated precision components leave Unit I Vasai Phata. No subcontracting. No vendor handoffs. One integrated sheet metal fabrication system under one roof.
Mill-Certified Material Sourcing
JSW and TATA primary certified coils in HR, CR, GI, and SS verified against Mill Test Certificates at Unit II Dhumal Nagar's 50-tonne certified digital weighbridge.
Cutting and Blank Preparation
3000W fiber laser cutting machine, CNC shearing, hydraulic shearing, and kachi light-gauge cutting produce net-shape blanks to ±0.1mm before any forming operation begins.
Forming and Fabrication
20 power presses for sheet metal stamping, CNC and manual press brakes for bending, and 6-machine welding division for structural and precision assembly at Unit I.
Surface Finishing and Dispatch
7-tank pre-treatment and three-oven powder coat system including crane-operated 4x10x10 ft oven. Class 5B adhesion verified on every batch before dispatch.
Engineering Reference
Sheet Metal Material Properties & Grade Reference
Sheet metal material properties - tensile strength, yield strength, and density of sheet metal - determine which grade to specify for each fabrication operation. Steel sheet metal (HR IS 2062, CR IS 513) covers most fabrication needs. Corrugated galvanized sheet metal (GI IS 277) handles outdoor corrosion environments. Sheet metal properties like density of metal sheet are critical for weight calculations in automotive and solar tracker applications. All grades below are available at Aero Enterprises Vasai.
| Sheet Metal Grade | Density of Sheet Metal | Tensile Strength | Yield Strength | Thickness Range | Gauge Ref | Action |
|---|---|---|---|---|---|---|
| Steel Sheet Metal - HR IS 2062 | 7.85 g/cm³ | 410 MPa | 250 MPa | 0.8 to 20mm | 18G = 1.27mm | View Operations |
| Steel Sheet Metal - CR IS 513 | 7.85 g/cm³ | 350 MPa | 210 MPa | 0.5 to 3.15mm | 18G = 1.27mm | View Operations |
| Corrugated Galvanized Sheet Metal | 7.85 g/cm³ | 280 MPa | 195 MPa | 0.40 to 4mm | 18G = 1.27mm | View Operations |
| Stainless Steel 304 | 7.93 g/cm³ | 515 MPa | 205 MPa | 0.5 to 6mm | 18G = 1.27mm | View Operations |
| Aluminium 5052 / 6061 | 2.70 g/cm³ | 228 MPa | 193 MPa | 0.5 to 6mm | 18G = 1.27mm | View Operations |
| Brass C260 / C360 | 8.50 g/cm³ | 525 MPa | 310 MPa | 0.3 to 3mm | 18G = 1.27mm | View Operations |
Thickness & Gauge Quick Reference Matrix
0.5 mm sheet metal - electronics enclosures, stationery hardware, kachi light-gauge cutting
18 gauge sheet metal - brackets, clamps, standard frames, furniture hardware
3mm sheet metal - heavy structural brackets, flanges, channels
5mm sheet metal - heavy plates, structural supports, press tooling bases
Solutions
Offered
LED Lighting
Housing shells, heat sink enclosures, driver compartment bodies, flood light mounting brackets, and mounting hardware requiring oxide-free laser cut edges, distortion-controlled thin-gauge welding, and outdoor powder coat finishing.
View Sector Processing ControlsTracker OEMs
Structural mounting brackets, pivot arm assemblies, channel section profiles, and torque tube support weldments for solar tracker systems requiring high-strength structural joints, consistent angular geometry, and corrosion-resistant finishing.
View Sector Processing ControlsAutomotive OEMs
Chassis brackets, body reinforcement components, skin panels, and deep-drawn structural parts in CR IS 513 DQ and DDQ grade for Tier-1 and Tier-2 automotive supply chain with MTC documentation and ASME compliant weld procedure records.
View Sector Processing ControlsFurniture Manufacturers
Wall unit panels, bracket hardware, shelf support profiles, folder brackets, and modular hardware in CR and powder-coated MS requiring consistent RAL colour across multi-batch deliveries.
View Sector Processing ControlsStationery Manufacturers
High-volume precision stamped hardware, binding mechanism components, thin-gauge strip blanks via kachi cutting, spot-welded assemblies, and powder-coated finished parts for consumer-facing stationery product lines.
View Sector Processing ControlsIndustrial & General Fabrication
Custom sheet metal enclosures, electrical panel bodies, HVAC support frames, industrial cabinet structures, clamp sheet metal hardware, and general engineering components across all material grades.
View Sector Processing ControlsFabricated Outputs
Sheet Metal Enclosures, Boxes & Clamps
Our sheet metal fabrication produces three major product categories for OEM buyers: sheet metal enclosure bodies and housings, sheet metal box assemblies (through laser cutting + notching + deep drawing), and clamp sheet metal components for pipe and structural applications. All products include full dimensional inspection against supplied sheet metal design drawings and sheet metal part drawing files - with sheet metal defects prevention built into the process through our 7-stage quality check.
Sheet Metal Enclosure
Fabricated sheet metal enclosure bodies for electrical panels, LED driver housings, control boxes, and industrial cabinets. Processes: laser cut → notch → bend → weld → powder coat. Supplied to drawing with dimensional report.
Sheet Metal Box
Deep-drawn and CNC-bent sheet metal box assemblies for instrument enclosures, storage trays, and structural containers. Sheet metal box corners are notched before bending for clean right-angle joints without material overlap.
Clamp Sheet Metal
Stamped and CNC-bent clamp sheet metal components: saddle U clamps, pipe clamps, cable saddles, and mounting clamps. GI IS 277 for corrosion resistance, MS IS 2062 for heavy structural clamping applications.
Sheet Metal Defects — Prevention Built In
Common sheet metal defects - springback, wrinkling, burr edge, surface scratching, and powder coat adhesion failure - are prevented by process design, not inspection. We review sheet metal design drawings for DFM risk before production to eliminate defects at source, not after.
Need Sheet Metal Drawings or Reference?
Looking for sheet metal drawings for practice PDF, sheet metal part drawing samples, or sheet metal operations ppt-style reference? Contact us - we share DFM reference packs and fabrication process guides for OEM engineering teams on request.
Request Reference PackFabricated
Components
The culmination of our integrated stamping, bending, and finishing lines: factory-ready industrial hardware.
L Patti Brackets
"High-volume stamped corner brackets in MS, GI, and SS 304 for structural assembly."
Saddle U Clamps
"Precision-bent pipe mounting clamp sheet metal hardware with GI 120 GSM corrosion coating."
Wall Unit Holders
"Laser-cut and powder-coated document display frames for industrial SOP management."