Steel Fabrication: Technology Shaping the Industry

August 13, 2024

Steel Fabrication: Technology Shaping the Industry

Steel production dates to 1800 BC, when early steel artefacts were found in Anatolia, Turkey. Over thousands of years, steel production developed exponentially, with inventors like Henry Bessemer pioneering the industry by developing the first process for manufacturing steel inexpensively, known as the Bessemer Converter.

The steel industry has been reshaped countless times, with innovations being made every day, further shaping it. Modern technology allows the production and fabrication of steel to be more efficient, stronger, and more reliable.

Here are a few examples of the innovations being made within the steel fabrication industry:

Automation & Robotics

The use of robotics within the steel industry is making a direct impact on the metal fabrication sector. Collaborative robots, also known as cobots, are becoming increasingly popular as they make processes more efficient and cost-effective. They are designed to work alongside human operators, making them well-suited for tasks in the steel fabrication industry, where precision, adaptability, and human oversight are essential. Cobots are equipped with sensors, cameras, and advanced spatial awareness software, allowing them to perceive their environment.

Collaborative robots have multiple applications:

Welding – They can perform welding tasks with precision and efficiency. They are also useful for repetitive welding, freeing up human welders for more complex tasks.

Plasma & Laser Cutting – Cobots can automate cutting operations, enhancing precision and efficiency. Their ability to work closely alongside humans allows for quick adjustments and customizations during the cutting process.

Milling & Drilling –  Milling and drilling tasks can be performed on steel components using collaborative robots, improving accuracy and speed. This capability makes them ideal for handling varying designs and specifications.

The use of automation and robotics in the steel fabrication industry is helping to redefine how projects are executed. By utilizing new technologies, companies can achieve significant improvements in efficiency and quality while remaining competitive in a rapidly changing industry.

In addition to collaborative robots, more industries are adopting CNC (Computer Numerical Control) programming, which is becoming increasingly popular in manufacturing due to its many applications. CNC programming provides automation and excellent machining quality.

Types of CNC Processes:

CNC Routing – Used for cutting, milling, and drilling, CNC routing is commonly employed by manufacturers. It is ideal for businesses that need to make precise cuts at high speeds. CNC routing can dramatically reduce production time and errors by introducing computer control within the machining process.

Plasma Cutting – Plasma cutting machines use a thermal cutting method that employs a stream of hot plasma to cut through electrically conductive materials. A jet of ionized gas is shot through an air-cooled nozzle at high speed. At the same time, an electrical arc is generated onto the surface and converted to plasma. These high-powered plasma torches can cut through stainless steel, aluminium, nickel, titanium, and other metals.

Laser Cutting – A non-contact, thermal process in which a laser beam is used to melt and cut through materials. A gas jet removes any molten particles while the material is cut by moving the beam or workpiece using computer controls. There are three laser types: carbon dioxide, neodymium, or yttrium-aluminium garnet. Laser cutters are popular in industries like automotive and manufacturing, as they provide high-level precision.

3D Printing & Additive Manufacturing

Additive manufacturing is the process of creating an object or part by building it one layer at a time. It is the opposite of subtractive manufacturing, in which an object is created by cutting away at a solid block of material until the final object is complete. Additive manufacturing can refer to any process in which a product is created through building, but typically refers to 3D printing.

In steel fabrication, additive manufacturing is a significant technological advancement that is transforming how steel components are designed, produced, and utilized across various industries. This new technology allows for the creation of complex geometric designs, efficient material usage, and rapid prototyping, offering numerous advantages over traditional manufacturing processes.

Metal additive manufacturing involves the creation of a physical part from a CAD (Computer-Aided Design) model using a process that deposits material layer by layer. Metal 3D printing produces parts with intricate, complex features that are difficult to create using traditional manufacturing methods. Metal 3D printing can produce parts with high density and mechanical strength properties, making it an ideal manufacturing method for the steel industry.

Examples of Additive Manufacturing Processes:

Vat Photopolymerization – An additive manufacturing process that uses a liquid polymer resin to construct layers, forming a model. Throughout the process, the polymer layers are cured by ultraviolet light, which hardens the resin while the model is moved upwards as each new layer is added and cured.

Photopolymerization technologies employ the use of liquid polymers that harden when exposed to light and are widely used in the coating and printing industries. One of the most common vat photopolymerization processes is stereolithography, a term used to describe a type of stereoscopic photography.

Vat photopolymerization has many applications, including the creation of surgical practice tools, prostheses, and dentistry components that are biocompatible.

Material Extrusion – is a process that uses a continuous feed of thermoplastic or composite filler material. The filament is heated to a molten state and then deposited layer by layer upon a building platform to create a 3D model. Material extrusion printers typically have a build platform and a printing nozzle head gantry within a three-axis system. The printing head gantry moves within the X and Y axes while the building platform moves within the Z axis.

The filaments can vary depending on the intended purpose of the print and can be used for applications such as gear printing, bearings, prototyping models, and automotive parts.

PolyJetting/Material Jetting – is a additive manufacturing printing process in which droplets of the building and support material are selectively jetted onto a build platform and cured using either ultraviolet light or heat. The material droplets are selectively deposited by jet printer nozzles to create a three-dimensional model, which is cured with light if photosensitive material is used or heat-cured for metal or ceramic parts.

Material jetting is a versatile manufacturing process that uses various materials, including photopolymers, waxes, and metals, to create functional metal parts and tools.

Binder Jetting – A 3D printing technique that involves the deposition of an adhesive binding agent onto thin layers of powdered material. During the binder jetting process, the 3D print head moves over the build platform, depositing binder droplets. When the layer is complete, the powder bed moves downwards, and the printer head then spreads a new layer of powdered

material. The binder jet printing process can work with various materials, such as metals, sands, and ceramics.

Powder Bed Fusion – allows for the printing of complex geometric products using heat, lasers, or electron beams to fuse powdered materials layer by layer, causing the powder to melt and solidify.

 

Computer-Aided Design

Computer-Aided Design (CAD) is a design technology used by engineers, architects, drafters, and designers to create precise drawings, plans, and models of physical structures and systems. CAD software enables the creation and optimization of designs over traditional manual drafting.

CAD software allows users to create highly precise drawings and models, ensuring accurate dimensions and proportions. This precision reduces errors and improves the quality of the final product while allowing designers to easily modify and iterate their designs.  CAD is an essential tool in many industries, revolutionizing the way products and systems are designed and produced and its ongoing development continues to enhance its capabilities and applications.

 

In conclusion, the steel fabrication industry has undergone transformative changes due to innovations in technology. From the introduction of automation and robotics to the rise of additive manufacturing and advanced computer-aided design (CAD) tools, these advancements have significantly improved the efficiency, precision, and capabilities of steel production. The integration of technologies such as collaborative robots, CNC processes, and 3D printing not only streamlines operations but also opens new possibilities for complex and customized designs. As these technologies continue to evolve, they will undoubtedly shape the future of steel fabrication, driving the industry toward even greater achievements.

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