How to Choose the Materials in Sheet Metal Fabrication

Blog / How to Choose the Materials in Sheet Metal Fabrication

Aug 01,2025

In sheet metal fabrication, a wide range of metal materials are available, including stainless steel, carbon steel, copper, cold-rolled steel, aluminum, galvanized steel, alloy steel, and hot-rolled steel. The abundance of options can make it challenging to select the most suitable material for a specific application.

Therefore, choosing the right sheet metal material is essential for successful product design and fabrication. The wrong material can lead to performance issues, faster corrosion, or higher costs. This guide outlines the most popular options and how to choose the best one for your application.

(source:ecoreprap)

1. Understand Your Sheet Metal Project Needs

Before selecting a sheet metal material, consider:

Does it need to be strength or durability？
Does it need to be plasticized?
Does it need a smooth surface or specific finish?
What's your budget and production volume?
Answering these will help you make an informed choice.

2. Common Sheet Metal Materials Introduction

Although there are many materials suitable for sheet metal fabrication, stainless steel, copper, aluminum, cold-rolled steel, and galvanized steel are the most commonly used in the market today. This is due to their balanced performance in terms of strength, durability, formability, cost-efficiency, and corrosion resistance.

(source: McAlpin)

Stainless Steel

Stainless steel is a high-strength, corrosion-resistant alloy commonly used in harsh or high-humidity environments. It offers excellent durability and a long service life, making it ideal for food processing, medical equipment, and outdoor structures.

Typical Use: Kitchens, architecture, marine parts

Cold Rolled Steel

Cold rolled steel is known for its high strength, smooth surface, and precision. It's easy to machine and weld, but it requires surface protection to prevent rust. Suitable for structural parts and indoor applications.

Typical Use: Automotive parts, appliances, furniture frames

Galvanized Steel (Pre-Plated)

Galvanized steel is cold rolled steel coated with a layer of zinc to resist corrosion. It has moderate strength and good outdoor durability, making it a cost-effective option for general-purpose use.

Typical Use: HVAC, fences, roofing, ducts

Aluminum Sheet

Aluminum is a lightweight, corrosion-resistant metal with moderate strength. It’s easy to form and transport, making it ideal for applications where weight and weather resistance are priorities.

Typical Use: Aerospace, electronics, enclosures, signage

Copper Sheet
Copper is a highly conductive, corrosion-resistant metal known for its excellent electrical and thermal performance. It offers good formability and antimicrobial properties, making it ideal for precision components and environments requiring high conductivity.
Typical Use: Electrical components, heat exchangers, roofing, decorative elements

3. Compare Different Types of Sheet Metals

Strength & Durability (Comparison Table)

Material	Strength	Durability	Notes
Stainless Steel	⭐⭐⭐⭐ (High)	⭐⭐⭐⭐⭐ (Excellent)	Excellent in both strength and long-term durability.
Cold Rolled Steel	⭐⭐⭐⭐ (High)	⭐⭐ (Low–Moderate)	Strong and rigid, but prone to rust if not coated.
Copper Sheet	⭐⭐⭐ (Moderate)	⭐⭐⭐⭐ (Good)	Offers moderate strength with excellent corrosion resistance. Naturally durable and forms a protective patina over time.
Galvanized Steel	⭐⭐⭐ (Moderate)	⭐⭐⭐⭐ (Good)	Slightly weaker than raw cold rolled steel due to the zinc layer, but much more durable due to corrosion resistance.
Aluminum Sheet	⭐⭐ (Low–Moderate)	⭐⭐⭐⭐ (Good)	Lightweight and corrosion-resistant. Strength varies by alloy, but generally lower than steel. Good for non-structural or weight-sensitive applications.

Summary:

Strength: Stainless Steel ≈ Cold Rolled Steel > Galvanized Steel ≈ Copper Sheet> Aluminum Sheet

Durability: Stainless Steel > Copper Sheet ≈ Galvanized Steel ≈ Aluminum Sheet > Cold Rolled Steel

Plasticity（Comparison Table）

(source: asmsheetmetal)

Material	Plasticity Level	Notes
Aluminum Sheet	⭐⭐⭐⭐ (Excellent)	Aluminum exhibits excellent plasticity, especially in pure or soft alloy forms. It performs well in deep drawing and complex forming, though it has lower strength.
Cold Rolled Steel	⭐⭐⭐⭐ (Excellent)	Cold rolled steel offers very good plasticity and dimensional precision. Its smooth surface and uniform thickness make it ideal for precision bending, stamping, and welding.
Copper Sheet	⭐⭐⭐⭐ (Excellent)	Exceptionally malleable and ductile. Easily shaped without cracking—ideal for complex designs and decorative work.
Stainless Steel	⭐⭐⭐ (Good)	Austenitic stainless steels like 304 are reasonably formable but require higher forming forces due to higher strength.
Galvanized Steel	⭐⭐ (Moderate)	While based on cold rolled steel, the zinc coating can crack or flake during intense forming, slightly reducing overall plasticity.

Summary: Aluminum ≈ Cold Rolled Steel ≈ Copper Sheet > Stainless Steel > Galvanized Steel

Corrosion Resistance（Comparison Table）

Material	Corrosion Resistance	Notes
Stainless Steel	⭐⭐⭐⭐⭐ (Excellent)	Forms a self-healing chromium oxide layer. Withstands moisture, chemicals, and salt.
Copper Sheet	⭐⭐⭐⭐ (Good)	Excellent corrosion resistance. Develops a stable patina over time that protects it from further degradation.
Aluminum Sheet	⭐⭐⭐⭐ (Good)	Naturally forms a corrosion-resistant oxide layer. Lightweight and won’t rust.
Galvanized Steel	⭐⭐⭐⭐ (Good)	Protected by a zinc coating that resists rust. Can wear off over time.
Cold Rolled Steel	⭐ (Very Poor)	No protective layer. Easily rusts unless painted or plated.

Summary: Stainless Steel > Copper Sheet ≈ Aluminum > Galvanized Steel >> Cold Rolled Stell

Surface Finish（Comparison Table）

Material	Surface Finish Quality	Notes
Cold Rolled Steel	⭐⭐⭐⭐ (Very Good)	Very smooth, uniform surface due to precision rolling. Ideal for painting and coating.
Stainless Steel	⭐⭐⭐⭐ (Very Good)	Naturally smooth and available in various finishes (mirror, brushed, matte). Aesthetic + durable.
Copper Sheet	⭐⭐⭐⭐ (Very Good)	Naturally elegant surface with rich color. Patinas over time for a rustic or artistic effect.
Aluminum Sheet	⭐⭐⭐ (Good)	Clean and decent surface, but softer—prone to scratches and dents unless anodized.
Galvanized Steel	⭐⭐ (Moderate)	Spangled or mottled appearance from zinc coating; not uniform or smooth.

Summary: Cold Rolled Steel ≈ Stainless Steel ≈ Copper Sheet > Aluminum > Galvanized Steel

Cost

When choosing sheet metal for manufacturing or construction, cost is a critical factor. However, comparing materials by price per kilogram alone can be misleading, especially when the density of each material differs significantly.

Materials have different densities, one cubic meter of stainless steel weighs far more than the same volume of aluminum. Even if aluminum is priced higher per kilogram, its lower density means it may still cost less per cubic meter. Therefore, evaluating sheet metals by cost per volume offers a more accurate comparison for many engineering and construction projects.

Here are the general price trends by volume:

Stainless Steel – Highest cost by volume due to both high density and relatively high price per kilogram. Widely used due to its high corrosion resistance and refined surface quality.

Aluminum – Lightweight and corrosion-resistant, often more expensive than steel by weight, but less costly than stainless steel by volume.

Galvanized Steel – Regular steel coated with zinc for corrosion protection. Moderately priced and suitable for outdoor use.

Cold Rolled Steel – The most economical option, offering good strength and surface finish. Widely used where corrosion resistance is not a top priority and surface protection (e.g., painting) is acceptable.

Copper Sheet – a premium material with high metal value. Cost-effective for electrical or aesthetic use, but not for bulk structural needs.

Summary: Price Ranking by Volume

Rank	Material	Notes
1	Stainless Steel	High density and high cost per kg
2	Copper Sheet	High density and expensive, both per kg and per volume
3	Aluminum	Low density offsets higher price per kg
4	Galvanized Steel	Affordable with corrosion resistance
5	Cold rolled Steel	Cheapest option by volume.

4. Sheet Metal in Environment & Application Match

Stainless Steel is perfect for harsh, wet, or corrosive environments like marine, chemical, and medical applications due to its excellent corrosion resistance.

Cold Rolled Steel works best indoors or in dry, controlled settings. It’s strong and smooth but needs coating to prevent rust.

Galvanized Steel is suitable for outdoor use with moderate corrosion exposure thanks to its protective zinc coating, common in roofing, fencing, and ducts.

Aluminum Sheet excels in lightweight, corrosion-prone environments such as aerospace, signage, and coastal areas where weight and rust resistance matter.

Copper Sheet performs well in both indoor and outdoor environments, forming a protective patina over time that enhances its corrosion resistance and visual appeal.

5.FAQs About Sheet Metal Materials

What material is the most commonly used in sheet metal forming?

Cold Rolled Steel

Due to its excellent formability, low cost, good strength, and ease of welding, it is ideal for producing precise, smooth-surfaced components used in automotive, appliance, and construction industries, easy to bend and shape.

What is the best metal material for sheet metal fabrication?

Stainless steel

Due to its high strength, excellent corrosion resistance, durability, and clean appearance, it is ideal for demanding and visible applications.

What sheet metal materials can be welded?

Most sheet metal materials, including cold rolled steel, stainless steel, aluminum, and galvanized steel, can be welded using various techniques like MIG, TIG, and Stick welding, with each material requiring specific considerations such as heat control, pre-weld cleaning, and protective gases.

6. Conclusion

Choosing the right sheet metal depends on your application, environment, cost, and performance needs. Stainless steel offers strength and corrosion resistance. Aluminum is lightweight and easy to shape. Galvanized steel adds rust protection at a low cost. Copper sheet delivers excellent conductivity and thermal performance, while cold rolled steel delivers high precision and a smooth finish when protected properly.

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