Ogis Engineering Pty Ltd

Casting

Casting is the process of pouring hot metal into a mould or die, allowing it to cool, harden, and take the desired shape. The mass manufacture of parts using the same mould repeatedly to produce similar goods is suitable for the metal fabrication process. There are numerous casting variations. Die-casting is the process of forcing liquid metal into a die rather than a mould, where the pressure retains the metal in place as it cures. The fast applications that this approach provides are its main selling point. Pouring molten metal into a mould is a permanent mould casting technique.

Cutting

Cutting a workpiece to divide it into smaller portions is a relatively typical method of metal production. While sawing is still the most common way to cut, more recent techniques include laser, waterjet, power scissors, and plasma arc cutting. Cutting might be the first step of a more involved fabrication process, or it might be the sole one.

Another method of cutting metal that employs a die is die cutting. In rotary die cutting, the material is cut using a rotating cylindrical die that is fed via a press. On thicker metal materials, flatbed die cutting is employed. When the die stamps down on the metal, it cuts out shapes.

Drawing

Tensile power is used in drawing to draw metal bending into and through a tapered die. The metal is thinned by the die's stretching action. Drawing is typically done at normal temperature and is known as "cold drawing," however the metal workpiece can be heated to lessen the effort needed.

When the finished result has a depth that is equal to or more than its radius, the procedure is referred to as deep drawing. It is typically used in conjunction with sheet metal fabrication to create hollow cylinder- or box-shaped vessels from sheets of metal.

Folding

Metal fabrication processes are those used to turn raw metals into finished goods, parts, and structures. Fabrications are frequently used to describe an item or items made using these procedures. Metal fabrication is done by manufacturing organisations utilising a combination of manual and automated procedures. These procedures turn raw metals into fabrications, which are finished metal objects.

Cutting Methods

Metal production involves the use of cutting methods. In cutting processes, a metal workpiece is divided into two or more portions, either entirely or partially. Shearing is a typical cutting technique used in the manufacture of metal. A worker can cut a metal workpiece cleanly and precisely using an alligator shear or bench shear.

Because it can separate a metal workpiece, like shearing, torching is sometimes regarded as a cutting technique. In the process of fabricating metal, torching can be done with laser cutters, oxy-fuel or plasma torches.

Bending Methods

Metal production techniques include bending as well as cutting. A metal workpiece is not physically separated during the bending process. Instead, it is employed to alter the metal workpiece's shape.

A hammer is frequently used to bend. Hammers have a flat, wide head that makes it possible to bend custom metal fabrication. Some hammers are portable, while others are machine-connected. The second kind, also referred to as a powered hammer, can exert more force than the previous kind. Using a press brake is another method for bending. A press brake is a particular kind of machine used to bend metal engineering workpieces, like sheet metal.

Combining Procedures

After an incredibly unique and unpredictable year, we have seen many changes in how people do business such as working from home, quarantining, and finding different ways to communicate with team members and customers. Metal fabricators in Australia have seen the industry holding strong during the pandemic with a lot to look forward to in 2021, not only because of the vaccine rollout and the confidence that we have in the government but also because of the exciting industry trends to look out for.

This year could be challenging for many organisations since they need to be more proactive in managing uncertainty and catering to a changed world post-Covid-19. As a leading metal fabrication company in Australia, we have put together predictions on the upcoming trends to watch out for this year.

Automation

Some companies within the industry are sceptical of automation as it could mean fewer job opportunities, especially with the unemployment issues due to Covid-19. We have seen metal fabricators, welding companies, metal benders and others also worried about the cost involved in incorporating automation processes into the business without considering the advantages such as higher output, increased productivity, more adequate use of materials, and improved product quality, enhanced safety, less labour time.

3D Printing

3D printing is a popular trend that has been adopted by metal fabricators due to the various improvements which lead to improved customisation and efficiency. With this technology seeing a big boom, we will also be seeing an expansion of printable materials.

Cybersecurity

While cybersecurity should have been obvious all along, it is becoming more of a concern now especially in the metal fabrication industry. Any machine is prone to be hacked, including CNC machinery so it is important to be prepared against any potential cybersecurity threats, and we are seeing metal manufacturers and fabricators now investing more in cybersecurity technology.

Reshoring

Instead of offshoring services overseas, we are now seeing businesses reshoring — which is the transfer of a business operation that was moved overseas back to the country from which it was originally relocated. This is due to the increase in foreign wages, exchange rates and the rising costs of overseas freight transportation. This means we will be seeing a positive transition with more opportunities in the metal fabrication industry in the future.

Robotics

A topic that has been discussed for decades but is now being increasingly adopted, especially for ‘collaborative robots’ which are also known as ‘cobots’. This is due to their ability in providing metal manufacturers and fabricators with safe, versatile, easy-to-use automation that supports human labourers. This means they work as ‘assistants’ to labourers instead of replacing them.

What Is Metal Fabrication?

Metal fabrication is a process involving the manufacturing of metal parts and products in a specific shape or form as required. It is a complex process that includes cutting, folding and shaping metal to create a finished part, then followed by welding and coating. The fabrication process can be used for mass production and custom metal projects that usually involve designers and engineers.

What Do Metal Fabricators Do?

A metal fabricator is required to read, study and interpret blueprints and specifications to understand the scope of the project. A range of tools is used to cut, align and weld metal including hand tools, flame-cutting torches and hammers, hence why personal protective equipment (PPE) has to be worn at all times. Advanced machinery such as CAD software and CNC machines may also be involved in the process. After the initial product process, a quality control review is performed to ensure that the quality of the fabricated metal is acceptable.

What Qualifications Do Metal Fabricators Need?

Some metal fabricators get their training on the job however, many others receive their qualifications by getting the required training at TAFE. The course will cover blueprint studies, metal and steel fabrication, welding techniques and industry safety regulations. To become a qualified metal fabricator, a 42 – 48 month apprenticeship is often required.

What Type Of Projects Do Metal Fabricators Work On?

Depending on the metal fabricators’ skillset and specialism, they may work on a wide range of products including electronic devices, vehicles and aircraft. Some metal fabricators may also exclusively work in factories, mining, construction and infrastructure.

Metal Fabrication Process

The process to fabricate metal products from raw materials is complex. Depending on the project specifications, the process may involve additional steps and alterations. However, the general metal fabrication process generally involves cutting, bending, moulding, welding and coating. We will look at the major steps in the fabrication process:

Cutting

Cutting is the first stage of any fabrication project after the blueprint has been studied. There is various way to cut raw metal, from using a basic saw to water jets, chiselling, plasma torches, die-cutting and laser. Cutting machines can be a huge operational cost, which is why during the initial stages of the project, machine cost-effectiveness should be factored into the project cost. For example, programmed CNC cutting will cost a lot more than using a plasma torch.

Bending

Metal and stainless-steel bending is performed manually or through electric tools to get the cut metal into the desired form. This needs to be performed at an appropriate angle to avoid failure or suboptimal performance.

Welding

Welding involves attaching 2 pieces of metal through a joint to achieve a larger structure. For certain complex projects, specialised welders will often be employed to ensure that the joint is suitable for the intended end-use. There are various ways to weld metal including structural welding, MIG and TIG welding.

Coating

Coating is the process of applying a layer to the exterior of the metal and is often referred to as metal finishing. This is done by applying a thin layer to the metal to improve its surface characteristics (improved durability and increased corrosion, abrasion and chemical resistance). Metal fabricators use a wide range of finishing depending on the material and application to improve their finish quality.

Stainless steel materials have common properties that make them ideal for building applications. They are readily formable and weldable, protected by a chromium oxide layer at their surface, as a result of a chemical reaction between chromium available in steel and the oxygen in the atmosphere. They do not require surface protection against corrosion, as in case of damage, the surface self-repairs in the presence of oxygen.

Some modifications can be added to this layer in order to produce modifications in the colour. There are many different types of surface finish on stainless steel. Some of these originate from the mill but many are applied later during processing.

While stainless steel could be used in different applications, quality surface finishes are critical for the application to succeed, since a rough surface finish can decrease the material’s corrosion resistance to that of a lower grade of stainless steel.

As there are many finishing options, you usually need professional assistance to help you decide which surface finish to choose according to the application of the stainless steel.

What is the most common stainless steel finishes?

2B Finish

This is the most common cold-rolled mill industrial finish of choice. It is a general-purpose cold rolled stainless steel finish and is commonly used for all applications when an aesthetic stainless steel display is not a primary requirement, except in difficult deep drawing applications. It’s a dull grey and is slightly reflective. It also serves as a starting point for many of the other polished stainless steel finishes.

Possible applications for 2B stainless steel finish include bakeware, chemical plant equipment, dye house equipment, flatware, laundry and dry cleaning as well as plumbing fixtures, refrigeration, sewage treatment, sheet metal products and vacuum drum dryers.

No . 4 Finish

No . 4 stainless steel finish is considered the main stainless steel finish for the light fabrication industry, used for work surfaces, handrails and for applications requiring good aesthetics. It has a low gloss, it’s the easiest to maintain, it’s produced with short parallel polishing lines, and it is mechanically polished with abrasives to provide the best overall stainless steel appearance. It’s also referred to as ‘satin’ or ‘finished’. It is considered a universal finish, being widely used for restaurant and kitchen equipment, storefronts and food processing and dairy equipment as well as architectural wall panels, beverage equipment, boat fittings, highway tank trailers, hospital surfaces and equipment, instrument and control panels.

No.8 Finish

A mechanical polish that provides a bright non-directional finish, obtained through finer abrasives and buffers to give a highly reflective finish. The grit lines of this stainless steel finish are considered much less visible, but they can be seen if the finish is examined closely. The resulting finish is mirror-like, and hence it’s referred to as “mirror” finish.

Applications of this stainless steel finish include clean rooms, column covers, mirrors, ornamental trim, press plates, reflectors, and signage and wall panels.

Electropolish

The electropolishing process produces a metal surface that is microscopically featureless, this results in a smoother, brighter and deformation-free stainless steel surface that has superior corrosion resistance.

Bead blasting

Bead blasting is ideal for stainless steel used within the marine and food industries and for the restoration of car and motorcycle parts, as it provides a dull finish which removes weld discoloration, through a smooth, natural finish without altering the underlying surface.

Stainless steel should be properly packaged for maximum protection during transport.

Floating reception desk by Ogis Engineering.

A statement piece of furniture, complete with custom perforated shelves for the reception area of a large international company. The look of the bespoke cantilevered desk appears as if it’s floating. The measurements and installation of this piece was critical to deliver the effects specified.

For more info, visit-

CNC stands for “Computer Numerical Control”, which is a high precision machine used for custom metal fabrication in order to make computer-controlled repeated movements. The concept is based on meticulous accuracy using computer-generated codes that are then converted to electrical signals, which in turn direct the CNC motors to make specific moves in small increments that are highly precise and repetitive. 

Expensive yet highly versatile, CNC machining milling can be customized to make pretty much anything they are asked to do, which makes them a great asset in the custom manufacturing industry to create parts. In the manufacturing industry, CNC machines can be a mill, lathe, router, welder, water jet cutter, laser cutter, grinder, sheet metal stamper or a robot for an assembly line.

Ogis Engineering has expertise in metal fabrication for over 50 years, and as we’ve seen the benefits of CNC machinery, we have invested in the latest CNC machines and advanced technology to stay on top of the metal fabrication industry in Australia.

Benefits of CNC Machines:

1. Optimal Productivity

CNC machines are highly productive, using this subtractive manufacturing technology, parts are created by removing material from a solid block using a variety of cutting tools. As they don’t rely on manpower after setup, they provide greater productivity than other machines that depend on manpower to make them work.

2. Accuracy and Consistency

A very high level of manufacturing consistency and accuracy is achieved with CNC machining, as there is no human operator, which eliminates the probability for mistakes for personal reasons, such as being tired, distracted or in a bad mood. This means high quality custom metal fabrication with minimal waste.

3. Agile Technology

When using CNC machines, you can make design changes on-the-go as required, without the need of expensive tooling, which means you can provide advanced custom fabrication without charging your clients a fortune, as well as adjusting your designs as required, without the time expenditure in tooling setup.

4. Reduce Labor Costs

CNC machines save money on labor costs, which saves metal fabricators money allowing them to offer affordable custom metal parts, since the machine works on their own, not requiring skilled machinists for operators, only supervisors.

5. Adaptability

With CNC machines, no design is too complex, even curves. Check our recent curving gate design. In fact, CNC machines might be the only solution to accurately and consistently machine around compound curves while maintaining tolerance and extreme consistency.

6. Minimal Waste

What Does A Sheet Meet Fabricator Do?

The day-to-day duties of a metal fabricator involve turning raw metal into the desired fabricated structures that can be used as part of a project or product such as medical devices and construction projects. Metal fabricators go through a detailed process with engineers and designers to achieve the desired end result. These steps are:

Thoroughly read the blueprint and drawings to understand the scope of the project and discuss with the engineering team any potential limitations/considerations

Assess where to cut, bend, form and assemble the metal parts by calculating the dimensions and tolerances required by the project

Use machinery and tools to fabricate the metal part. This can be completed by using CNC machining

Assess the quality of the fabricated metal and test whether it meets the defined specifications

Sheet Metal Fabrication Process

Metal fabrication projects can differ however, the general sheet metal fabrication process involves:

Designing

Specifications and designs are provided to the metal engineers before the project kick-off. This is a critical step in defining the success and outcome of the fabrication. It is important that enough time is provided before the project kick-off to ensure that there is no time and money wasted.

Programming

Programming starts once all the project is signed off. The design is altered into a programmable language that the machine can take action from and start developing.

Cutting

After the programming is completed, a laser is used to cut the metal as it provides much higher precision and requires less time in comparison to hand cutting.

Punching

Depending on the required specifications, a CNC machine may be used to punch holes into the metal.

Bending

This process is often referred to as CNC folding. During this process, the fabricated metal part is clamped and pressured so that it can reach the desired metal form.

Assembly

This phase will depend on the final product’s requirements as it could involve simple welding or integration of other elements including electrical parts.

Powder Coating

To achieve a durable coating, the fabricated metal will go through a heating process that involves the application of electrostatic powder followed by curing.

Sheet Metal Fabrication Applications

Sheet metal fabrication is an extremely common process due to its versatile applications. Common applications include:

Cold Rolled Steel

Used in applications where aesthetics are important. You will often find it in domestic and commercial applications including home appliances, metal furniture, filing cabinets and school lockers. It is also commonly used for building steel sheds, industrial buildings and car parks.

Hot Rolled Steel

Hot rolled steel is known for its strength and is often found in structural components like beams, truck frames, vehicles’ seat frames, cross-sections, rail tracks and sheet metal but can also be seen in public art fabrication and art sculptures. It is also widely used in agriculture equipment.

Stainless Steel

Stainless steel is one of the most popular choices due to its strength, flexibility and high corrosion resistance. It is often found in applications including air exhaust systems, kitchen appliances, storage tanks, pipes, surgical and dental instruments.

Aluminum

Aluminum is light when compared to other metal types and is often used in transportation and home construction due to its low maintenance and thermal efficiency.

For more info, visit-

TREE OF LIFE SCULPTURE

Ogis Engineering is a specialist engineering company specializing in tube and pipe bending as well as metal fabrication. Based in Western Australia, we supply to a range of industries and have the ability to work with all types of materials including carbon and alloy steel, stainless steel, aluminum and Fabrications. For more info, visit-

TREE OF LIFE SCULPTURE

Showcasing Ogis Engineering's new sliding gate design and brass balustrades.

Ogis Engineering is a specialist engineering company specializing in tube and pipe bending as well as metal fabrication. Based in Western Australia, we supply to a range of industries and have the ability to work with all types of materials including carbon and alloy steel, stainless steel, aluminum and Fabrications. For more info, visit-

Ogis Engineering is a specialist engineering company specializing in tube and pipe bending as well as metal fabrication. Based in Western Australia, we supply to a range of industries and have the ability to work with all types of materials including carbon and alloy steel, stainless steel, aluminum and Fabrications. For more info, visit-

What is Galvanized Steel?

Galvanized steel is steel sheets covered in zinc, which makes it rust-resistant. It is one of the most common kinds of steel on the market today. A reason for its popularity is its durability, the zinc coating gives it corrosion resistance. Most modern buildings are built using galvanized steel frames. It is also a very common material used in the solar and automotive industries. The process of creating galvanized steel is hot-dipping steel into a zinc coating solution. This coating protects the steel from corrosion and general surface scratches. Galvanized steel is extremely versatile, it can be punched, pressed, welded and bent into shape to suit the project’s requirements.

How to maintain and protect galvanized steel?

It is crucial to understand the general care and maintenance materials that are required when working with galvanized steel. It is important to avoid exposing galvanized steel to conditions where the pH is below 6 or above 12 as it can cause the coating to corrode more aggressively. Galvanized steel products should be kept away from corrosive environments including brass and copper metals as this can also affect the quality of the material. Do not wash galvanized steel unnecessarily, as harsh cleaning products can wash away the protective film on the steel. This can eventually reduce the life of the steel. Environmental factors can also contribute to the deterioration of the steel, the steel should not be exposed to the rain or sun. To keep the integrity of the steel, we recommend that it is stored in a dry location with adequate ventilation.

Common issues when working with galvanized steel

There are several common issues that arise when working with galvanized steel including corrosion and coating issues. Galvanized steel can also pose health issues, and should be done with the proper knowledge and training.

Health issues when welding galvanized steel

Welding can be extremely hazardous and the appropriate welding personal protective equipment should be worn and used at all times. This includes protective equipment like helmets, gloves, leather jackets, and steel toe boots. Welding galvanized steel also requires the use of a respirator so that the zinc oxide fumes are not inhaled. It is also recommended to only weld in a well-ventilated area to minimize inhaling these toxic fumes.

For those welders that ignore safety risk a number of long-term health issues including metal fume fever, lung and brain cancer that is caused by the small lead content on the galvanized coating forming oxide fumes, which is released during the welding. It is important that the welder is properly trained and follows strict welding procedures to minimize the risk. Along with checking all the correct personal protective equipment is worn at all times, the welding area should be evaluated for risks and hazards.

How to improve the safety of welding?

When undertaking a welding job, it is important to wear appropriate equipment including a respirator and full protective clothing to ensure that no skin is exposed. A well-ventilated area is essential to minimize the toxic fumes that are emitted during the welding process. Appropriate eyewear should be worn at all times, this includes safety glasses with side shields and ear protection as it protects the welder from exposure to welding rays.

Welding galvanized steel can be hazardous for those that are not fully trained or wearing the correct safety equipment. The right welder can ensure that all safety precautions are taken so that there will be no delays in your project.

OGIS Engineering Pty Ltd is a business that specializes in metal fabrication. It is located in Sydney, NSW's outer suburbs. The company is a specialist in heavy-duty structural steelwork, both for commercial and industrial applications. Other services offered by the company include material handling solutions such as overhead cranes and security gates, machine guarding, machine dock levelling, machine guarding, custom stainless-steel workstations, and custom steel workstations. For more ingo, visit:

What Is Stainless Steel?

Stainless steel is an alloy consisting of iron and chromium that is sometimes combined with other metals such as nickel. It can be used for several different applications thanks to its unique fire, corrosion resistance, recyclability, durability and mechanical properties. This is why it is commonly found in everyday items and used in commercial applications across several industries including transport, medicine and logistics.

Steel consists of iron and carbon while stainless steel contains 11% to 13% of chromium, less than 1.2% carbon and other alloying elements. Elements can be added to stainless steel to improve certain properties depending on the application and project specifications. Stainless steel forms a chromium oxide layer when exposed to oxygen, which protects it from any damage.

Can You Weld Stainless Steel?

Many people wonder if they can weld stainless steel themselves. While the answer is yes, the process to weld stainless steel is not simple as it is very efficient at retaining heat, which makes the welding process much more complex and often requires a professional welder.

What Type Of Welding Is Suitable For Stainless Steel?

Stainless steel can be welded using different welding methods including shielded metal arc (MIG), gas tungsten arc welding (TIG) and spot welding depending on the specified outcome requirements.

TIG Welding

TIG welding stands for Tungsten inert gas welding. TIG uses a non-consumable tungsten electrode to run a current through the metals that need to be joined and may also use a filler metal. It uses an electrical arc (DC or AC depending on the metal) to melt the steel and inert gas to prevent weld oxidisation. TIG welding is good for thinner metal pieces up to 5mm thick and is a technique sensitive welding process in terms of timing and controlling the torch.

TIG welding can be used for a variety of applications but is primarily used for pipeline and pipe welding. It is also commonly used in the aviation, aerospace and metal fabrication industries. TIG welding is more effective at welding thin and special materials such as titanium.

Spot Welding

Spot welding is also known as resistance spot welding and is performed by welding 2 or more metal sheets together using pressure and heat that is generated from an electric current. It is commonly used to permanently attach 2 separate pieces of metal at specific points.

Spot welding is commonly used in a range of industries such as automotive, rail and construction. It is a fairly straightforward process, which makes it suitable for applications that requires a high volume of output.

MIG Welding

MIG welding is an arc welding process that uses a continuous solid wire electrode that feeds into the weld being made and becomes the filler material that helps join the 2 metals together. It can be used to weld thicker materials (up to 40mm) and heavy-duty objects more efficiently when compared to TIG welding. As a result, MIG welding is often easier and less technique sensitive.

MIG welding is primarily used for production work (furniture and displays etc.) and industrial applications. It is better suited for applications that are smaller or have a lower volume of work.

What Is The Best Welding Method?

There is no straight answer to this question as this would highly depend on the application. To decide which welding method you should use, you need to consider the following:

Welder’s skill level

Desired aesthetic appearance

Metal thickness

Labor and machinery costs

MIG and spot welding is much more affordable and faster to complete while TIG welding works the best for thinner metals or items that require an aesthetic appeal.

How Difficult Is It Welding Stainless Steel?

Stainless steel retains heat much more efficiently than other metals and excessive welding heat can warp and even distort the stainless steel when it is cooling down. This can cause irreversible damage including marks and blemishes that cannot be repaired. The surface can also be scratched easily and precautions should be taken when handing stainless steel.

These are the different techniques that can be used to weld stainless steel. It is important to choose the right welding depending on the application use and production volume. Our team at Ogis Engineering is equipped to help you with your welding project. For more info, visit