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Advanced Manufacturing

Advanced Manufacturing Technology

We provide advanced manufacturing services in technologies like 3d printing, CNC machining, vacuum casting, injection molding, etc.

On Time Project Delivery

on time project delivery


With locations in all over Australia we can assure lightning fast delivery.

Australia Wide Expandation

Australia wide expandation


Zeal 3D is present in
Victoria, NSW, Western Australia,
Queensland and Tasmania.

Experienced Engineers


Team of expert engineers with more than 15 years of experience.

PORTFOLIO

METAL FABRICATION SOLUTIONS AVAILABLE AT ZEAL 3D

Sheet Metal Manufacturing

Precision Metal Sheet Fabrication

Trolleys and Material Handling

Trolleys and Material Handling

Custom Platforms and Equipment

Metal Fabrication Solutions

Precision Pipe & Tube Welds

Metal and Welding

Metal Fabrication and Welding

Metal Fabrication Solutions

Zeal 3D's Tailored Metal Fabrication Solutions:

Precision Metal Sheet Fabrication:

When it comes to working with sheet metal, the team at Zeal 3D are experts. We work with sheet metal day in and day out because it's just such a versatile material. It's strong yet flexible, durable yet workable. No matter what kind of product or structure you need fabricated and assembled, we can make it happen with precision sheet metal work. Whether you need something designed from scratch or an existing design built out, our team has the expertise to deliver top-notch sheet metal components.

Trolleys and Material Handling:

Keeping materials moving smoothly is key for any operation. That's why we specialize in customized trolleys and other material handling equipment. We'll analyze your workflow and design the perfect ergonomic solution - from small hand trucks to massive industrial trolleys. Our fabricators and welders will build it specifically for your environment and work processes using techniques like welding to create a rugged final product. The goal is always maximizing safety and efficiency for your material transport.

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Custom Platforms and Equipment Fabrication:

Platforms, access structures, equipment mounts—you name it, we can build it with precision metal fabrication. These custom pieces are essential for supporting operations, allowing personnel access, and integrating new equipment installations. Our welders and fabricators are pros at constructing sturdy, code-compliant platforms and frames that check every box on your requirement list. We'll ensure an ergonomic design for a seamless user experience too.

Precision Pipe & Tube Welds:

Our welding experts are masters at joining pipe and tube sections with flawless, leak-proof welds. This level of precision is critical in many industries like construction, oil/gas, automotive, and aerospace where pipe/tube integrity is paramount. We follow all relevant codes and techniques for whichever materials and pipe gauges you're working with. From delicate thin-walled tubing to heavy-duty structural pipe, our certified welders can handle it all.

Custom Metal Fabrication and Welding Projects:

Let your imagination run wild - we can take on any kind of custom, specialty fabrication project. Our team thrives on finding creative solutions to unique challenges and requirements. We'll bring together the right minds from design, engineering, welding, and fabrication to strategize and execute on even your most ambitious vision. Whether it's a sculptural art piece, proprietary equipment, or something completely new, we have the skills to make it a reality using metal.

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Metal Fabrication Services Across Diverse Industries

Automotive Industry:

The auto sector is greatly reliant on metal fabrication for producing durable and high-performance components. Here are some potential parts that can be manufactured with metal fabrication:

  • Body panels (doors, hoods, fenders)
  • Chassis and frame components
  • Suspension parts (control arms, knuckles)
  • Powertrain components (engine blocks, cylinder heads)
  • Exhaust systems
  • Fuel tanks
  • Brake components

Aerospace Industry:

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Precision and strength are paramount in the aerospace sector, making metal fabrication an indispensable process.

  • Airframe components (fuselage sections, wing spars)
  • Landing gear components
  • Engine components (turbine blades, casings)
  • Hydraulic system parts
  • Fuel system components
  • Structural brackets and fittings

Construction and Architecture:

Metal fabrication is a cornerstone of the construction and architecture industries, providing durable and aesthetically pleasing solutions for various building components.

  • Structural beams and columns
  • Curtain walls and cladding systems
  • Railings and staircases
  • Decorative architectural elements
  • Roofing and siding components
  • HVAC ductwor

Industrial Machinery:

Metal fabrication facilitates the making of durable and long-lasting equipment in every aspect of industrial machinery.

  • Machine frames and housings
  • Gears and sprockets
  • Conveyor system components
  • Robotic arm components
  • Tool holders and fixtures
  • Hydraulic and pneumatic system parts

Energy and Oil & Gas:

The energy and oil & gas sectors demand durable and corrosion-resistant components capable of withstanding harsh environments. Metal fabrication provides solutions that meet these demanding requirements, ensuring safe and reliable operations.

  • Pipelines and fittings
  • Pressure vessels and storage tanks
  • Offshore platform components
  • Drilling equipment components
  • Pump housings and impellers
  • Valve bodies and actuators

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Metal Fabrication in Automotive Industry
Metal Manufacturing

How Does Metal And Fabrication Work?

Designing: The first step is translating your ideas into a tangible form. Before we begin designing, we sit down with you to understand your preferences. Our designers then skillfully craft the 3D model using the industry-leading SolidWorks software, allowing you to visualize and refine every detail.

Programming: With the design finalised, it's programmed into a machine-readable format. Our experts lay out the components across metal sheets in a 2D pattern, optimising material usage for efficiency.

Cutting: Now the real creative work begins - literally. We utilise state-of-the-art laser cutting technology to precisely cut through the sheet metals, following the programmed designs with laser-focused accuracy.

Punching & Forming: For components requiring perforations, ridges or custom shaping, our CNC punch presses come into play. As a part of sheet metal fabrication, these powerful machines use specialised tools to punch holes or form the metal into the desired profiles and contours.

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Bending: To transform flat metal into its final 3D shape, we move to the bending phase. Depending on the complexity, parts may be bent using manual press brakes, automated panel benders or robotic cells - each applying controlled force to curve the metal exactly as designed.

Welding: For assembled structures and products, we employ various welding and fabrication methods such as MIG, TIG, spot and projection welding. Our certified welders meticulously join components with strong, durable welds.

Assembly & Integration: This is where all the pieces come together. Whether it's a basic weld assembly or a complex integration with wiring, hardware installation and more, our technicians carefully construct the final product through each assembly step.

Finishing: To provide a flawless surface and enhance durability, we often complete the process with a factory-grade powder coating finish. After electrostatically applying the specialised powder, it's cured under heat to create a robust final coating.

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Advantages of Metal Fabrication

Greater Strength and Durability: Don't settle for components that fade or fail. Our fabricated metal parts are engineered to withstand the harshest conditions, staggering forces, and relentless wear and tear year after year. This resilience translates into exceptional longevity and an outstanding return on your investment.

Design Flexibility and Customisation: Metal fabrication knows no bounds when it comes to design complexity. Through cutting-edge techniques like laser cutting and CNC machining, we transform even the most intricate concepts into tangible reality with astonishing accuracy down to the finest detail.

Dimensional Accuracy and Precision: Modern metal fabricating techniques, particularly those involving CNC machining and laser cutting, deliver exceptional precision and dimensional accuracy. This ensures parts fit together perfectly and function flawlessly, crucial for applications requiring tight tolerances.

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Scalability for Every Project Size: Metal fabrication caters to projects of all sizes. Whether prototyping visionary ideas or executing large-scale production runs, our metal fabrication capabilities flex to your requirements. We take care of your projects from conceptualisation through full metal manufacturing, maintaining stringent quality control at every phase.

Material Versatility: Steel, aluminium, titanium - we'll guide you towards the perfect custom sheet metal for your project's unique demands. Whether you prioritise strength, weight, heat resistance or corrosion protection, we'll compose the ideal high-performance alloy.

Cost-Effectiveness: While excellence requires an investment upfront, the long-term value of our fabricated parts redefines cost-effectiveness. Expect minimal maintenance and repair costs coupled with incredible longevity for unbeatable lifetime value.

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Metal and Welding
Trolleys and Material Handling

Metal Fabrication Materials

Carbon Steels: Affordable and versatile ferrous alloys containing varying amounts of carbon to influence strength and hardness properties. Common grades fabricated include:

  • Mild Steels like 1018 and 1020
  • High-Strength Low-Alloy grades such as A36, 4130, 4140, and 4340
  • Other Alloy Steels like 8620, D2 Tool Steel, and more

Stainless Steels: Corrosion and oxidation-resistant steel alloys thanks to a minimum 10.5% chromium content. Offered in a range of grades such as:

  • Austenitic options like 304, 316, and 316L
  • Ferritic grades such as 430 and 439
  • Martensitic including 410 and 420
  • Duplex stainless like 2205 and 2507

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Aluminium: Lightweight, conductive and corrosion-resistant non-ferrous metal. Aluminium fabrication involves alloys that can be fabricated and heat treated for increased strength:

  • 6000 series like 6061, 6063, and 6082
  • High-strength 2000 and 7000 series alloys like 2024 and 7075
  • 5000 series marine grades such as 5052, 5083, and 5086
  • Cast tooling alloys including A356 and A357

Titanium: Extremely strong, light and corrosion-resistant refractory metal with a high strength-to-weight ratio ideal for aerospace and medical applications. Titanium alloys offered:

  • Grade 5 (6AL-4V)
  • Grade 9 (3AL-2.5V)
  • Grade 23 (6AL-4V-ELI)

Copper Alloys: Excellent electrical and thermal conductivity combined with corrosion resistance. Brasses, bronzes, and other copper alloys can be fabricated such as:

  • Alloy Brasses like 360 and C36000
  • Aluminium Bronzes
  • Beryllium Copper

Exotic Alloys: For exceptional mechanical strength, temperature resistance, or corrosion resistance, speciality high-performance alloys are also available including:

  • Nickel-based Superalloys like Inconel, Hastelloy, and Monel
  • Cobalt Alloys such as Haynes and MP35N
  • Tungsten Alloys

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What Are the Different Grades Of Steel?

At Zeal 3D, we fabricate using a wide range of steel grades - each carefully selected to provide the optimal properties for your project's requirements.

Carbon Steels: The most common steel type, categorised by their carbon content which influences hardness and strength.

  • Low Carbon (Mild) Steels - Up to 0.3% carbon content. Grades like 1018 and 1020 are ductile and easily formable.
  • Medium Carbon Steels - Between 0.3-0.6% carbon for increased strength and wear resistance. Examples are 1040, 1045.
  • High Carbon Steels - Over 0.6% carbon makes grades like 1080 and 1095 very hard but less ductile. Used for cutting tools and dies.

Alloy Steels: Contain alloying elements like chromium, nickel, molybdenum which enhances properties like strength, hardness, corrosion resistance:

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  • Low-Alloy Steels - Up to 8% alloying content. Grades like 4130, 4140, 8620 offer great strength and toughness.
  • High-Alloy Steels - Over 8% alloys. Tool steels like D2, A2 have impressive hardness and heat resistance.

Stainless Steels: Contain at least 10.5% chromium for enhanced corrosion and oxidation resistance.

  • Austenitic (300 series) - Grades like 304, 316 are the most common austenitic offering good formability.
  • Ferritic (400 series) - 430 is an affordable stainless with less formability than austenitics.
  • Martensitic (400 series) - 410, 420 are very hard and strong after heat treatment.
  • Duplex - 2205, 2507 combine high strength with superior corrosion resistance.

Tool Steels: Specially engineered high-alloy steels for enhanced wear resistance in tooling applications.

  • Water/Oil-Hardening - Like O1, A2, D2
  • Shock-Resisting - Including S7
  • High-Speed Tool Steels - M2, M4

Other speciality stainless and alloy steels like Maraging steels and Precipitation Hardening grades are also available for unique applications.

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Custom Metal Fabrication
Metal Fabrication Services

Metal Fabrication Services

From delicate prototypes to high-volume production runs, our skills are matched only by our obsession with quality. At Zeal 3D, we'll ensure every detail, selecting premium materials and using a mix of time-honoured techniques and cutting-edge technology to deliver metal components products that adhere to the strictest standards regarding functionality, fit, and finish.

More than just a vendor, we're a partner that works hand-in-hand with you from concept to completion. We'll diligently study your designs, ask questions, and develop a true understanding of your goals. Then we'll apply our passion and expertise to manifest that vision with precision and craftsmanship that is second to none. Invest in excellence and multigenerational quality with Zeal 3D's metal fabrication services. We'll craft a metal masterpiece as special as your brand.

What is Metal Fabrication?

The term "metal fabrication" describes the process of making structures from raw metal materials. This highly skilled craft combines various metalworking practises to cut, bend, assemble and join different types of metals like steel, aluminium, brass and more.

Why Choose Zeal 3D for Metal Fabrication Services?

Great Expertise: Metal fabrication is more than just operating machines - it's an art perfected with experience. Our team lives and breathes this craft, having honed their skills on countless projects across industries. With years of experience, our metal fabricators, engineers and designers understand how to maximise the unique properties of each metal for optimal strength, precision and performance.

Cutting-Edge Technology: You can't achieve pure fabrication mastery without premier equipment and technology. That's why we've invested heavily in cutting-edge laser cutters, CNC machines, welding metal gear and more. Precision, efficiency and repeatability are baked into everything we make.

Scalability for Every Project: Whether we're prototyping a single part or firing up a massive production run, our capabilities can scale to match your needs. We've finely tuned our processes to operate at any volume without missing a beat on quality or lead times. From fast-paced low-volume jobs to complex, high-quantity orders, our flexibility ensures we have you covered without compromise.

Material Versatility: With a vast roster of over 45 premium metal varieties, we eliminate material constraints

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from the equation. Whether you need exceptional strength, light-as-a-feather capabilities, corrosion resistance or any other key properties, we'll material-match to hit your specs and performance targets dead on.

Uncompromising Quality Assurance: For us, quality isn't an added bonus or nice-to-have - it's an unwavering requirement baked into our core processes. We never cut corners, with rigorous inspection and testing protocols like 3D scanning to ensure every part meets the strictest standards. You can rest easy knowing your fabricated components will perform superbly, even in the most demanding conditions.

Tailored Solutions: We recognise that each project is distinct, presenting a different set of demands and challenges. To address this, we adhere to a collaborative strategy, partnering closely with our customer base in order to comprehend their desired outcomes. Following that, using our resources and experience, our team creates specialised solutions to produce parts that are beyond your expectations.

Collaborative Partnership: Our partnership approach means we're invested in your success from day one. We'll roll up our sleeves, immerse ourselves in your project needs, and work hand-in-hand to map out the best path. You'll always be up to speed through transparent communication. And we'll leverage our deep knowledge base to steer you towards smart innovations and improvements along the way.

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