Choosing the right material determines the quality, durability and cost-effectiveness of your sheet metal products. Our guide shows which metals are suitable for what, highlights current trends such as sustainability and high-tech materials and provides practical tips for your material decisions - compact, easy to understand and application-oriented.
Introduction
Every successful sheet metal part starts with the right material. It is the cornerstone for the functionality and durability of your products. But it is also crucial for its manufacturability and cost-effectiveness. A well-informed choice saves time and money and avoids problems later on.
Whether you are an engineer, designer or purchaser - this guide will help you. It will help you make the best choice of material for your sheet metal project.
Material overview in detail: Which metal suits your project?
To make your decision easier, we will introduce you to the most common sheet materials. Find out more about their specific properties, typical applications and how they behave during processing. If you have any questions about sheet metal processing, you can find out more on our services page.
Steel is a versatile metal that is characterized by high strength, good weldability and excellent robustness. It is ideal for use in metal construction, mechanical engineering or vehicle construction.
Thanks to special protective coatings, such as galvanizing or powder coating, sheet steel also offers reliable corrosion protection. As a result, the material remains durable and dimensionally stable even under heavy use and weathering. Steel can be precisely cut, bent and shaped.
Steel is therefore a popular material in sheet metal processing. It is used for stable, resilient and durable components.
Typical applications:
Enclosures, frames, carriers, switch cabinets, vehicle construction (non-visible parts).
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Suitability for machining processes:
Excellent for laser cutting, punching, bending and all common welding processes.
Common varieties:
- S235JR (1.0037): The standard structural steel, versatile and cost-effective. Ideal for general constructions and components where corrosion protection can be provided by painting or galvanizing.
- S355JR (1.0045): A higher-strength structural steel that can bear more load with the same dimensions. Perfect for applications that require greater rigidity or load-bearing capacity.
Stainless steel convinces through Exceptional strength, high corrosion resistance and elegant appearance. The stainless material is ideal for applications where hygiene, weather resistance and durability are important, for example in mechanical engineering, architecture or the food industry.
Stainless steel sheet can be precisely cut, edged, shaped and welded. The natural passive layer provides lasting protection against rust - ideal for projects where quality and stability are important.
Typical applications: Food industry, medical technology, chemical plants, architecture, kitchen equipment, maritime applications.
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Suitability for machining processes:
Well suited for laser cutting, punching, bending and welding.
Common varieties:
- AISI 304 (1.4301): The most commonly used stainless steel. Offers good general corrosion resistance and is easy to weld and form. Ideal for indoor and outdoor applications without extreme environmental conditions.
- AISI 316 (1.4401): With the addition of molybdenum, this stainless steel offers significantly higher corrosion resistance, especially against chlorides (e.g. salt water) and many acids. The first choice for maritime applications, the chemical and food industries
Aluminum alloys convinces through sits low weight, high stability and excellent corrosion resistance. Thanks to the natural oxide layer, aluminum sheets are rust-free and ideal for outdoor use.
The sheets can be easily cut, bent or welded and offer high dimensional stability. Aluminum sheets are used in vehicle construction, mechanical engineering, façade construction and interior fittings. They are durable, easy to process and combine strength with optimum protection from the elements.
Typical applications: Aerospace, vehicle construction (lightweight construction), electronic housings, heat sinks, facade cladding, consumer goods.
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Suitability for machining processes: Very suitable for laser cutting (with special settings), punching and bending.
Common varieties:
- AlMg3 (EN AW-5754): A highly weldable and formable alloy with good corrosion resistance. Ideal for general vehicle and mechanical engineering as well as maritime applications.
- AlCuMg2 (EN AW-2024): An age-hardenable alloy with very high strength. Often used in aircraft construction, but is more difficult to weld and less corrosion-resistant than 5xxx alloys.
Copper sheets are very popular in sheet metal working because Copper has the highest electrical and thermal conductivity of all common metals. Due to its ductility and good formability, copper sheets are easy to process and form.
Copper also impresses with its Corrosion resistancewhich makes it ideal for long-lasting applications. Over time, however, a characteristic patina forms, which changes the appearance of the material but increases its protective function. Copper sheet combines functionality and aesthetics.
Typical applications: Electrical engineering (busbars, contacts), electronics, heat exchangers, decorative elements, architecture.
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Suitability for machining processes: Good for laser cutting (demanding due to high reflection), punching and bending.
Common varieties:
- E-Cu57 (CW004A): Purest copper form for maximum conductivity.
Brass/bronze: Copper alloys that improve strength and specific properties.
What are the trends in material selection for sheet metal processing in 2025?
The Sheet metal processing will undergo significant change in 2025, characterized by technological advances, increasing sustainability requirements and individual application needs. The selection of the right material will play a key role in meeting the increasing demands for efficiency, durability and environmental compatibility. The most important trends in material selection in sheet metal processing can be divided into three core areas: Extended use of advanced materials, Sustainability and resource conservation and the Application-related, targeted material selection.
A clear trend in sheet metal processing in 2025 is the increased use of innovative materials that not only offer greater strength, but also better corrosion resistance and an optimized ratio of weight to stability. These include in particular
- High-strength aluminum alloys like Aluminum 5083, 5754 and 7075which are characterized by their excellent strength and corrosion resistance. Aluminum is particularly in demand in vehicle construction, aviation and shipbuilding, where weight savings are crucial.
- Aluminum-lithium alloys, which are increasingly used in aircraft construction because they combine high strength, low weight and excellent corrosion resistance.
- Special stainless steelsincluding the tried and tested varieties 304 and 316Loffer improved corrosion resistance, especially for use in medical technology, the food industry and the maritime sector.
- High-strength steel like S235JR or S355JR enables lighter constructions with high stability at the same time - a significant advantage in mechanical engineering and load-bearing structures.
- Titanium sheets are becoming increasingly important for demanding applications, particularly in plant engineering, medical technology and aviation, as titanium offers an outstanding strength-to-weight ratio and is extremely resistant to corrosion.
- Carbon fiber reinforced plastics (CFRP) are revolutionizing lightweight construction. Their high strength, extremely lightweight construction and resistance to corrosion and fatigue make them the ideal choice for highly stressed components, e.g. for bridges, façades or in the automotive sector.
In 2025, sustainability will no longer be an optional criterion, but an integral part of material decisions in sheet metal processing. Companies are increasingly focusing on resource-conserving and environmentally friendly materials in order to reduce CO₂ emissions and promote a circular economy. Key developments are:
- Increased use of recycled materialsespecially with steel and aluminum. Recycled aluminum and steel not only reduce waste, but also conserve resources and significantly reduce the ecological footprint.
- Stainless steel as a sustainable optionStainless steel is considered a particularly environmentally friendly material due to its durability, corrosion resistance and high recycling rate.
- Optimized use of materials thanks to intelligent software solutionsthat minimize waste during cutting and machining processes. Less material waste means less raw material consumption and lower costs.
- Energy-efficient manufacturing processes also help to further improve the carbon footprint of sheet metal processing.
The targeted choice of materials depending on the intended use will become even more important in 2025. Companies are placing greater emphasis on selecting materials that are precisely tailored to the specific requirements of the end product. Important factors here are:
- Strength and hardness for load-bearing or highly stressed constructions.
Corrosion resistance for use in damp, aggressive or maritime environments. - Low weightparticularly important for aerospace, vehicle construction and lightweight construction.
- Good machinabilityto ensure efficient production processes.
- Optics and surface finishespecially for visible components such as facades or design elements.
- Special propertiesfor example, the highest electrical or thermal conductivity of copper, which is the preferred material in electrical and energy technology.
Our tips: Find the perfect material for your sheet metal processing
Are you unsure which material is right for you? Use our simple guide to make a preliminary selection and tailor the choice of material to your specific needs.
- What is the main requirement for your component?
- [High strength / rigidity]
- [Low weight]
- [Maximum corrosion resistance]
- [Best electrical/thermal conductivity]
- [Lowest costs]
- In which environment is the component used?
- [Interior, dry]
- [Outdoor area, normal weather conditions]
- [Humidity / condensation]
- [Salt water / chemicals]
- [High temperatures]
- Which processing methods are primary for you?
- [Laser cutting / punching]
- [Bending / Forming]
- [Welding]
- [Surface finishing (lacquer, powder, etc.)
Based on your answers, we can give you initial recommendations for suitable materials and start the discussion about the optimum solution.
Advice & offer: We are here for you!
Material selection is complex - let us master it together. Our team of experts will support you with in-depth knowledge and practical experience. Whether you need specific properties, want to optimize costs or are looking for support with the selection for complex projects:
Contact us today for a personal consultation or request a non-binding quote for your sheet metal project directly!
FAQs on sheet metal and material
Sheet metal working is a versatile trade in which metal sheets are cut, bent, formed and joined together to create functional products. Both thin (from 0.006 inch) and thick (up to 0.25 inch) sheets can be processed. Techniques include cutting (e.g. lasering), rolling, punching, hemming, welding or riveting. Common materials are aluminum alloys, stainless steels and various types of steel, but also copper and brass. Applications range from the industrial to the hobby sector, e.g. for car body parts or household appliances. It is characterized by accuracy, efficiency and versatility.
Sheet metal working, a versatile process for transforming metal sheets into functional parts, typically involves five main stages.
- Preparation phase: Here, the metal surface is cleaned and freed from impurities.
- Design phase: Detailed drawings or 3D models of the end product are created manually or using CAD software.
- Production phase: The sheet metal is cut, bent, formed and welded to obtain the desired shape
- Final phase: Surface treatments such as powder coating or polishing are carried out to provide functional and protective properties.
- Assembly phase: The manufactured parts are assembled using techniques such as gluing, welding or mechanical fastening. This process is characterized by its accuracy, efficiency and versatility.
Sheet metal processing uses a variety of techniques to shape sheet metal. The main processes include cutting, often using laser cutting, plasma cutting, shearing or sawing. Sheet metal is also bent and formed into the desired shape using folding benches or universal machines. Punching is used to create holes or patterns. Welding or riveting are used for permanent connections. Other techniques include rolling, seaming (hemming) and curling. Finally, the edges are often finished with files or grinding machines.
As a rule, untreated carbon steel (e.g. S235JR) is the most cost-effective material. However, the total costs can change if expensive surface treatment or complex processing steps are required.
Carbon steels are considered to be very easy to weld. Many types of stainless steel and aluminum alloys are also weldable, but often require specific welding processes and specialist knowledge to avoid distortion or loss of quality.
Corrosion resistance is crucial for outdoor applications. Stainless steel (especially AISI 316 for harsh conditions) and aluminum (due to its natural oxide layer) are the first choice here. Carbon steel requires a high-quality coating or galvanizing.
Yes, absolutely! Our experienced engineers and production experts will be happy to advise you on material selection and optimize your design for the best possible manufacturability and cost efficiency.
