Are you a metal working enthusiast? Do you relish the prospect of creating intricate pieces of art, signs, or logos using metal? Are you in the industry and want to mark or simply work with metal for various use cases?
Welcome to the various applications involved in this industry. In this article, we will focus on the latest technologies as applied in metal cutting. At the end of this article, you should be able to differentiate between the terminologies and also choose the right application that suits your needs.
From metal marking, engraving, stamping, and etching to grinding and milling, we will introduce some of the options that are out there. We will also direct you to other blogs and sites where you can learn more about these applications. You can follow the links we provide here for amazing blogs and YouTube videos.
What is metalworking?
Metalworking is the application of various processes to metals to create desired parts, line assemblies, or large-scale structures. Many large-scale projects, from oil rigs, ships, and bridges to small parts of things like engines, and all the way to jewelry, are made through metalworking.
There is therefore a need to use a wide range of skills, processes, and tools, and when working with metals, to get the desired results. The processes can be categorized into three main categories, namely forming, cutting, and joining.
Cutting involves processes in which material is brought to a specified form by removing material using various kinds of tools. The finished part should fulfill set specifications in terms of dimensions, artwork, design, and aesthetics.
Cutting produces two products: the waste and the finished part. After cutting metal, the waste is called metal chips or excess metal. Cutting processes further fall into three major categories:
- Those that produce chips, also known as machining
- Those that burn, oxidize, or vaporize material
- Miscellaneous: a mixture of both, or other processes like chemical cutting.
Drilling a hole in a metal part is the most common example of a chip-producing process. Using an oxy-fuel cutting torch to separate a plate of steel into smaller pieces is an example of burning. Chemical milling is an example of a specialty process that removes excess material by the use of etching chemicals and masking chemicals.
Cutting Technologies
Many technologies exist for cutting metal. Sample a few:
- Manual technologies: e.g., sawing, chiseling, shearing
- Machine technologies: e.g., stamping, grinding, and milling
- Welding/burning technologies: burning by laser, oxy-fuel burning, and plasma
- Erosion technologies: by water jet, electric discharge, or abrasive flow machining.
- Chemical technologies: Photochemical machining or etching.
As can be seen, there are many types of cutting metal work, and collecting reading resources is a good starting point to enable you to harness all the available technologies for a good grasp of this amazing field.
You can also check artmachining.com for laser cutting services, learn more information about aluminum or stainless steel CNC laser cutting.
A look at some metalworking techniques
We cannot be able to cover all these technologies in one article. However, we will select six of these techniques and explain what they are, their respective tooling, and possible use cases.
（1）Metal Marking
Direct Part Marking (DPM) is a range of technologies that are used to create permanent markings on metal for the purposes of part traceability, labeling industrial pieces, ornamentation, or any other purpose.
Marking metal is as old as the invention of smelting techniques when man started using metal tools like axes and spears. However, current technologies have evolved to allow humans for the first time to create high precision and intricate marking for all conceivable use cases. Marking is achieved through various techniques, including engraving, embossing, die casting, stamping, etching, and grinding.
Handheld Dot Peen Marking Machine HS-PE02-B
The HS-PE02-B is a portable metal marking machine with an integrated removable battery to accomplish on-site metal marking. The integrated touch screen simplifies operation and allows for effortless and precise marking of machines and parts. Meet your various industrialized marketing needs.
（2）Metal Engraving
Engraving is a technique that is used mainly to either incise patterns, wording, drawing, or coding on a metal surface, in order to have a permanently marked product or to enable the use of an engraved metal to print engravings on paper.
Engraving is achieved through the use of two main technologies, which are laser and mechanical engraving.
Machines Used
Are you researching how to engrave metal? Do you want solutions for different applications you are interested in? A suitable laser metal engraving machine could be just what you are looking for.
Despite being very versatile and easy to use, laser technology gives you the highest quality in metal engraving because it is computer-aided, and its application is precisely predetermined on various surfaces for the best results.
Mechanical engraving can be done by hand, or through the more reliable use of pantographs or Computer Numerical Control (CNC) machines. We found a collection of such machines at Gravograph. It has many advantages, including replicability and low operating costs.
However, it is pricey, as the equipment and computers used may come at a price of around $75k-$100k. Also, it is not as versatile as laser engraving, and die breakage or outage may mean losing a half-engraved piece.
Use Cases
You can read more about laser metal engraving and its use cases from our related blog. We use metal engraving for;
- Fine Art
- Grave-marking
- Print-plate making
- Existing 3D engravers
- Personalized Jewellery
- Photopolymer laser imaging
- Industrial Marking Technologies
- Engraving trophies in sporting competitions
Gravotech LS100 Laser Engraver
The LS100 is designed with an enclosed and compact structure, making it suitable for both beginners and experts. It includes an integrated air compressor and automatic touch sensing for easy operation. This laser engraver works with a variety of materials, including plastics, wood, glass, and other organic materials, as well as painted surfaces, offering flexibility across multiple projects.
（3）Metal Stamping
Metal Stamping is not a subtractive process. It uses dies to fold flat metal sheets into shapes.
Mostly, household appliances like pans, spoons, cooking pots, and plates are made using a combination of casting and cutting. There are mechanical and hydraulic metal stamping machines.
Metal sheets of up to ¼ inch made of stainless steel, aluminum, zinc, and copper are cast, punched, flanged, and cut by these machines into 3D objects. They have very high product turnover rates due to the relative ease with which they carry out the casting and cutting.
Presses can be arranged in series to work on metal stock, converting them to very specific parts using different synchronized operations until the finished parts are cut off and dispensed from the processing line.
Machines
The presses can be used in many applications because of the wide range of items they can produce. They come in different sizes and designs, and most are for industrial use.
Precious metal stamping machines also exist. There are many in this industry. In the US, for example, you could try Norstan in Wisconsin, Nesper in Georgia, or HPL Stampings Inc., from Illinois.
Usually, what you want is to send your artwork and metal sheets (or specification thereof) to a company that does metal stamping, and then get the product of your liking.
Use Cases
The presses are used to make roofing materials, household utensils, medical equipment, machine parts, and even coins. Their products are used in as diverse industries as medical, electronic, electric, automotive, military, HVAC, pharmaceutical, commercial, and machine-building markets. There is much more information about these machines on Thomasnet.com.
JL21G Series C-Frame High-Speed Presses
The JL21G Series C-Frame High-Speed Presses offer high operational efficiency. The press’s rugged frame and precision engineering ensure consistent performance and minimal downtime. Its automation features and advanced control system simplify complex tasks and enable high-quality output to be maintained with less manual intervention.
（4）Metal Etching
Etching can be achieved either through photochemical or laser processes.
Laser Etching
Are you in search of the latest technologies in metal etching? Laser etching is what you need, then.
This technology has evolved exponentially over time. It involves the process of creating high-precision designs by the use of coherent amplified light beams on a metal surface.
Laser is the cleanest mode of etching and arking as it does not involve the use of corrosive reagents, bits, or noise-intensive abrasive processes. It is simply the laser beam vaporization of material to create exact images or texts as instructed through a computer program.
There are also emerging smaller and smaller equipment that can be used by researchers and enthusiasts for laser, as the technological advancement allows for cheaper options.
HeatSign 20W Mini Fiber Laser Marking Machine
The HS-MFL20 machine weighs only 15 kg and offers high flexibility in various work environments due to its compact and portable design. It can be controlled via computer or mobile phone, offering convenience and flexibility with Wi-Fi connectivity options. Suitable for marking metals, rubber, certain plastics, and more, making it ideal for industries like electronics, automotive, and more.
Chemical etching
The chemical enables the process to expose parts of a metal piece to a strong acid (or mordant) to cut patterns on it and create a design in intaglio (or incised) in the metal. It is subtractive in nature, using etchant chemistry to produce complex, high-precision metal components.
In a basic metal etching, the flat metal surface is covered with a special coating that is resistant to acid, and select parts of the coating are scratched away by hand or mechanical means. The metal is then placed in an acid reagent bath.
The acid erodes the part of the metal not covered by the coating, leaving a pattern identical to the one scratched into the coating. The workpiece is then removed and cleaned, and inks can be used to print the pattern on paper, etc. Photoetching involves the photomechanical application of the acid-resistant layer on the metal surface.
The main difference between this method and other mechanical or hand scratching techniques before etching is that the acid-resistant layer applied is also treated with irradiation to create a photoresist layer and therefore assist in the production of highly precise and replicable patterns.
Machines
There is a wide range of machines in this field. Some of the best laser etching machines can be found at HeatSign. They range from Fiber laser, CO2, and UV machines.
We mention them here because their website is very easy to navigate and they have a very fast customer service chat that gives relevant feedback immediately you start chatting. Other brands can also be accessed from Alibaba, Amazon, and eBay.
Use Cases
Etching can be used together with scanning to produce replicas of artifacts for restoration. This replication is also used to create costumes and movie sets. Etching is an important part of jewelry making and the gift industry.
Masteretch Model 635 Chemical Etching Machine
The Masteretch Model 635 Chemical Etching Machine offers versatility with configurations for developing, etching, and stripping. It features a 635mm wide conveyor system with precise speed control via a DC shunt motor and digital readout. The machine includes dual spray bars with quick-release jets for even etching, and essential safety features such as a low liquid level cutout, magnetic interlock, and fume extraction. Designed for mobility on a castored base, it has a compact size of 1100mm x 900mm x 1100mm.
（5）Metal Grinding
Metal grinding is a physical abrasion using a cutting tool, commonly used to finish off rough edges, deburr, smooth welds, remove chips, create sharp edges, or create unique finished looks to a metal part.
It is mostly the last bit of operation to a part that has undergone engraving, stamping, etching, or any other forms of metalwork. Interestingly, this bit of metalworking is extraneous but labor-intensive. It can be mitigated by the use of a proper choice of design, material, and in-process operations.
Machines
There are six main types of grinding machines with different types of applications.
- Belt Grinder: basically uses a motorized belt coated with abrasive material, which is then used on a metal surface to achieve the desired finish.
- Bench Grinder: These are very cheap and handy tools. They mostly involve a bench-mounted motorized grinding wheel, which, when rotating, can sharpen farmyard tools, round metal cut edges, etc.
- Cylinder. This type of grinder works mostly with cylindrical, elliptical, or a combination of these two. It consists of a rotating grinding wheel and an object manipulation system that feeds the workpiece to the grinder. Some models have inbuilt cooling systems to keep the workpiece as close to normal temperature as possible for best results.
- Surface Grinder: These are the most commonly used grinders. Surface grinding is mostly a finishing operation. The grinders use a rotating abrasive wheel to smooth flat metal surfaces and give them a more refined look or a desired functional surface.
- Bit Grinder: These grinders are mostly used to sharpen various types of drill bits.
- Jig Grinder: These machines are used to finish jigs, dies, and fixtures. Their primary function is in the work of grinding holes for drill bushings and grinding pins. They can also be used to complete complex surface grinding to finish work started on a mill. These grinders allow us to make complex geometrical drill shapes in various tools with very high precision and accuracy.
Use Cases
As seen in the examples of grinders above, grinding can be used in many applications, including the making of engine blocks, aero, ship, and automotive parts, making dies for other metal applications, etc.
HFS NC Series Conventional Surface Grinder
The HFS NC Series Surface Grinder features touchscreen programmable grinding cycles and automatic wheel dressing for precise, efficient grinding. It supports both semi-automatic and automatic operations, suitable for everything from small custom jobs to large-scale production. Key features include a magnetic clamping plate, extensive X-axis and Z-axis travel, and variable spindle speeds for versatile grinding needs. Safety interlocks and a robust control system ensure safe, user-friendly operation, making it ideal for precision surface finishing in tool manufacturing and custom part production.
（6）Metal Milling
Milling shapes metal or other materials by shearing material off a metal surface to form the final shape. Milling machines consist of a milling cutter that rotates on a spindle axis and a worktable that can move in multiple directions with respect to the work surface.
The spindle usually moves vertically as the worktable moves along the X and Y axes to create intricate patterns as designed. Milling machines can be operated either manually or under computer numerical control (CNC).
They perform complex operations, including slot cutting, planning, drilling and threading, rabbeting, routing, etc. Two common types of mills are the horizontal mill and the vertical mill.
Use Cases
Milling machines are mainly used for drilling, reaming, and tapping various metal parts. It is the primary operation used to make engine blocks, gear parts, threads, and male-female parts for metal joinery.
They are mostly used on flat surfaces, though they can also produce irregular surfaces. They can also be used to make drill bits, bore, cut gears, and produce slots. They also make grooved holes into which bolts can be fastened.
X6323A X6323B Universal Turret Milling Machine
The X6323A X6323B Universal Turret Milling Machine offers diverse table sizes (230×1067 mm or 230×1246 mm) and extensive travel capacities (long travel up to 850 mm, cross travel 305 mm, vertical travel 350 mm) for precise multidimensional control. It features a standard R8 spindle with optional ISO 30/ISO40 and variable speeds up to 4200 rpm, suitable for various materials. The robust head swivels 90 degrees and tilts 45 degrees for complex tasks, while safety interlocks and a user-friendly control panel enhance safety and usability. This machine is ideal for sectors like tool manufacturing, mold making, and prototype development.
General Machine Purchasing resources
If you want to find machines to buy, here are some of the best resources to get your equipment;
e-commerce platforms
Amazon: Catch purchase information on marking, engraving, etching, grinding, and milling.
eBay: Information on eBay for all these technologies is available. You can also find their offerings for marking, engraving, etching, grinding, and milling.
Alibaba: marking, engraving, etching, grinding, and milling options are also available in Alibaba.
Made-in-China.com gets a selection of grinding,
Possible Online Resources
If you are looking to expand your knowledge on any of these technologies, you can visit several online resources where finer details of these technologies are discussed, more detailed analyses of the outcomes of each technique are carried out, and even pointers to upcoming updates of any of the technologies are revealed.
Here are just a few;
Autodesk 123D
Final Thoughts
The metalworking world is diverse, with many use cases for anyone interested in working with metal. In this article, we have mainly been involved with the cutting technologies that are used in the industry to create artful designs and other functional properties on metal.
From metal marking for traceability, milling, grinding, and engraving to stamping and etching, we have given you the starter material to what these techniques are so that you can delve deeper into any of them if you so wish.
And we have also given you several pointers on blogs and other materials you can either watch on YouTube or read. Hopefully, you will have a more pointed direction in your journey in metalworking after you read this post!
FAQs
The guide categorizes metal cutting into three types. What are they?
The three major categories of metal cutting are chip-producing processes, also known as machining; processes that burn, oxidize, or vaporize the material; and miscellaneous specialty processes, such as chemical cutting.
What is the key difference between how a laser and a CNC machine engrave metal?
The key difference is the tool they use. A laser engraving machine is a non-contact method that uses a high-energy beam of light to vaporize the material. A CNC machine is a contact-based method that uses a physical, rotating cutting tool to carve into the material.
For creating household appliances like pans and cooking pots, which metalworking technique is most commonly used?
For creating these types of 3D objects from flat metal sheets, the guide states that metal stamping is the most common technique used. It is a non-subtractive process that uses dies to fold and shape the metal.
The text describes 'laser etching' and 'chemical etching.' How are their processes different?
Their processes are very different. Laser etching is a clean, non-contact process that uses a laser beam to vaporize the material’s surface. Chemical etching is a subtractive process that involves covering the metal with a special coating and then placing it in an acid bath to erode the exposed areas.
What is the primary function of a metal grinding machine in the metalworking process?
The primary function of a grinding machine is as a finishing tool. The guide explains that it is most often the last bit of operation performed on a part to finish off rough edges, deburr, smooth out welds, or create sharp edges.
What is a 'Jig Grinder' and for what specific task is it used?
A Jig Grinder is a specialized type of grinding machine. Its primary function is for the high-precision grinding of holes for things like drill bushings and grinding pins. It is also used to finish jigs, dies, and fixtures.
How does a metal milling machine shape a piece of metal?
A milling machine shapes metal by using a rotating milling cutter to shear material off a workpiece’s surface. The guide explains that the worktable typically moves along the X and Y axes while the spindle moves vertically, which allows it to perform complex operations like slot cutting, drilling, and threading.
For marking a very large, heavy, and immobile metal part, which specific machine is recommended?
For marking a large and immobile part, the guide recommends the Handheld Dot Peen Marking Machine HS-PE02-B. Its key feature is that it is a portable, battery-powered unit that can be brought directly to the part for on-site marking.
