Metal fabrication processes explained

Nearly every custom metal fabrication job moves through the same five stages.

Flow diagram of five fabrication stages: cut, form, join, machine and drill, finish.

Common processes
Stage	Methods	Typical use
Cutting	Laser, plasma, waterjet, oxy-fuel, saw, shear	Blanks, profiles, plate parts
Forming	Press brake, plate rolls, tube bending, punching	Brackets, enclosures, curved parts, frames
Joining	MIG (GMAW), TIG (GTAW), stick (SMAW), flux-core, rivets and bolts	Assemblies and structures
Machining	Drilling, milling, tapping	Holes, fits, threaded features
Finishing	Powder coat, paint, hot-dip galvanizing, polishing, passivation, anodizing (aluminum)	Corrosion protection and appearance

The Bureau of Labor Statistics describes cutters as using an electric arc, plasma, or burning gases to cut and trim metal, and welders as choosing a process based on factors such as the metals being joined.¹

Questions

What is the difference between MIG and TIG welding?

MIG (gas metal arc welding) feeds a wire electrode and is fast for steel. TIG (gas tungsten arc welding) uses a non-consumable tungsten electrode and separate filler, and is slower but more precise, which suits thin material, stainless, and aluminum.

Laser, plasma, or waterjet?

Laser is precise and fast on thin to medium sheet. Plasma is economical on thicker steel. Waterjet cuts almost any material without heat, which avoids heat-affected zones.

U.S. Bureau of Labor Statistics, Occupational Outlook Handbook, “Welders, Cutters, Solderers, and Brazers,” https://www.bls.gov/ooh/production/welders-cutters-solderers-and-brazers.htm, read November 11, 2026. ↩