How to Choose the Materials in Sheet Metal Fabrication
11 min
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. Stainless Steel vs Aluminum Alloy in Sheet Metal Fabrication
When choosing materials for sheet metal fabrication, stainless steel and aluminum alloy are two of the most frequently compared options. Each material offers distinct advantages in terms of strength, weight, corrosion resistance, cost, and manufacturability. Understanding these differences is essential for selecting the right material for your specific application.
Strength and Weight Comparison
Stainless steel is well known for its high strength and hardness, making it suitable for sheet metal parts that must withstand heavy loads, mechanical stress, or impact. Its high density, however, results in heavier components, which may not be ideal for weight-sensitive designs.
Aluminum alloy, by contrast, has a density of roughly one-third that of stainless steel. While its strength is generally lower, it offers an excellent strength-to-weight ratio, especially in alloys such as 6061 and 7075. This makes aluminum sheet metal ideal for applications where reducing weight is a priority.
Typical takeaway:
- Choose stainless steel for load-bearing or high-strength requirements
- Choose aluminum alloy for lightweight structures and mobility-focused designs
Corrosion Resistance and Environmental Performance
Stainless steel contains chromium, which forms a self-healing oxide layer on the surface. This gives it exceptional corrosion resistance, even in humid, chemical, or marine environments. Grades such as 316 stainless steel are especially suitable for aggressive conditions.
Aluminum alloy also offers good corrosion resistance by forming a natural oxide layer. It performs well in outdoor environments and does not rust like carbon steel. However, in highly corrosive or chemical-heavy environments, stainless steel typically provides longer service life.
Typical takeaway:
- Stainless steel: harsh, wet, chemical, or marine environments
- Aluminum alloy: outdoor, general industrial, and lightweight applications
Processing Difficulty and Manufacturability
From a fabrication perspective, aluminum alloy is generally easier to process. It offers better formability, higher thermal conductivity, and lower cutting resistance, which reduces tool wear and machining time during bending, stamping, or CNC machining.
Stainless steel is more difficult to process due to its higher strength and lower thermal conductivity. It often requires greater forming force, stricter process control, and higher tooling costs. However, it delivers superior durability and structural integrity once formed.
Typical takeaway:
- Aluminum alloy: easier forming, lower processing cost
- Stainless steel: more challenging fabrication, higher process stability requirements
Cost Considerations in Sheet Metal Processing
Material cost is influenced not only by price per kilogram but also by density, processing difficulty, and scrap rate.
- Stainless steel tends to have higher material and processing costs, especially for thick or complex parts.
- Aluminum alloy may be more expensive per kilogram, but its lower density often results in lower overall cost per part, particularly in lightweight designs.
Budget-sensitive projects often favor aluminum, while performance-critical applications justify the higher cost of stainless steel.
Typical Applications and Use Cases
Stainless steel sheet metal is commonly used for:
- Food processing and medical equipment
- Chemical and marine components
- Structural or load-bearing parts
Aluminum alloy sheet metal is commonly used for:
- Aerospace and transportation components
- Electronic enclosures and housings
- Lightweight panels and architectural elements
How to Choose Between Stainless Steel and Aluminum
| Factor | Stainless Steel | Aluminum Alloy |
|---|---|---|
| Strength | High | Moderate |
| Weight | Heavy | Lightweight |
| Corrosion Resistance | Excellent | Good |
| Manufacturability | More difficult | Easier |
| Cost | Higher | More economical for lightweight parts |
Stainless steel is ideal for applications requiring strength, durability, and corrosion resistance, while aluminum alloy is better suited for lightweight, cost-sensitive, and easily formed sheet metal parts.
5. 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.
6.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.
7. 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.
Need help choosing or sourcing the right material? JLCCNC delivers custom metal services with precision. Only need to upload the 3D models, and use our simple quote tool to get instant pricing.
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