Reprinted and Modified From The Fabricator

Accurate Perforating doesn't just make holes anymore. It provides entire perforated and fabricated sheet metal components. The 200-employee Chicago manufacturer has done much to stand out in a consolidated sector.

The perforating industry once consisted of numerous small players clustered around Chicagoland and Pennsylvania. The shops were initially founded to serve the agricultural equipment needs and (especially in Pennsylvania) mining sectors. But over decades, the business changed. The perforation process itself had become viewed as a commodity service, and that, in turn, led to consolidation. Today, only a handful of prominent players remain, and one of them is Accurate Perforating (AP), a 200-employee operation based in Chicago.

But about a decade ago, AP started to follow a new path. Managers wanted the company to produce more than just the perforated sheet. They tried to fabricate and assemble that sheet into something larger and more complex.

Today, the company is no longer just about making holes; it's about making components that OEMs can place easily into their final assemblies and contractors can quickly install onto buildings. That's far different from what the company was right decades ago when a scrap peddler named Ralph Cohen fell in love with perforating—not for the hole-filled sheets the process produced, but what those sheets left behind.

FOR LOVE OF THE SLUGS

Before launching APC in 1942, Cohen had no intentions of becoming a perforator. He reveled in the deal—buying scrap low and selling it high—and some of his largest sources for scrap happened to be the perforation houses around Chicago.

"He was always a peddler at heart, and he became fascinated with his perforating clients because of the amount of scrap they generated," said Aaron Kamins, Cohen's grandson (on his mother's side). "He fell in love with the byproduct—the slugs that he would get from the perforators, and he said, 'You know, I could develop those slugs myself.' So he put in his first machine to generate those slugs."

During the early years, the perforation work complemented Cohen's primary scrap business, but over the years, this gradually shifted more toward perforation. APC moved into its facility in 1952 and remained a small enterprise for decades. Then, in 1982, managers jumped on an opportunity to purchase Standard Perforating, a competitor just a few miles away that had just undergone a labor dispute with its union and was struggling financially. APC moved Standard Perforating's employees and machines over to its facility. "That doubled the size of the business overnight," Kamins said, adding that in 2002, APC purchased another Chicago-based perf house, Semrow Perforated Products. 

FOOTHOLD IN FABRICATION

For decades, APC has performed shearing—and it's not an everyday shearing process, either. Some shearing occurs automatically in a separate station, connected to the press control, as the sheets emerge from the die.

Specific jobs, such as one in which each panel is a different size, each with an unperforated margin around the edge, require a secondary shearing process. A technician places pins in the last row of perforations, which stick up and allow the shearing operator to gauge off the edge of the perforation (the critical dimension) and not the edge of the blank.

Besides shearing, though, the company's fabrication offering in the 1990s was a little extensive, and it certainly didn't include comprehensive assembly or welding services. Between 2000 and 2005, Mike Beck, Vice President of Sales and Engineering, helped bring in machines to expand APC's capabilities. "Our existing customer base's demand for fabrication was growing," he said.

Then, in early 2005, came a phone call that accelerated the company's push into fabrication. It was a contractor for the new American Airlines World Gateway terminal at JFK, and he had a problem. The new concourse had thousands of perforated ceiling panels. The perforations weren't unusual—0.125-inch-diameter holes punched in 0.050-inch-thick aluminum; the holes' staggered orientation (lining up horizontally but not vertically) aided noise reduction and airflow.

Fit-up between the panels was critical, and this was what the contractor called about. Thousands of panels had arrived at the site, perforated and with edges flanged, but when they were installed, some bowed slightly. Many panels had dimensions different from what they should have been, which wreaked havoc on fit-up. On top of all this, many panels arrived at the site severely damaged.

The contractor sprung the question: Could APC provide dimensionally accurate perforated panels? One more thing—the grand opening is just 90 days away.

APC dove into the job, manufacturing 17,000 panels with acoustic backing material and the proper perf patterns that ensured noise reduction and proper airflow. It worked with a corrugated box manufacturer on the packaging so the panels would arrive at JFK without a scratch.

Most significant, at least regarding the company's evolution, was APC's work with Advanced Display, a precision sheet metal fabricator in Chicago. At the time, the fabricator focused on the point of purchase (POP) display industry (hence the fabricator's name) but contracted with different companies as well, including APC.

Advanced Display had the precision press brakes and forming expertise this job required, plus the capacity to manufacture the panels within the short lead time required. The 2- by 5-foot perforated panels required a tight dimensional tolerance in length, width, and edge-flange depth.

Working together, APC and Advanced Display churned out 170,000 square feet of perforated panels, fabricating and painting them on time to be painted and installed before the grand opening in July 2005, when then-New York City Mayor Michael Bloomberg spoke below the space-age, dramatically white ceiling of the new Terminal 9. 

HOLEMAKING ON THE LEVEL

Because the perforation press creates a large area of holes in one hit with one die, it tends to distribute forming stresses evenly, but the unequal stresses are still there, and this causes distortion. The plate that is 0.25 in. thick emerges from the perf press almost in a half-moon shape. It curls the entire sheet, but it curls it evenly.

By making hole-intensive patterns on the turret punch press, technicians can minimize stress by punching in different areas of the sheet, starting away from and moving toward the clamps. They use machine features that change the approach speed of the ram or use the stripper to hold the workpiece in place before the punch contacts the sheet surface. All this helps distribute the stress induced by the punching force. All the same, for many jobs, the distortion is, again, still there.

For this reason, the company sends all perforations and other hole-intensive jobs through one of seven high-powered Herr-Voss Stamco precision levelers, which equalize the stresses to produce a flat, perforated sheet. The levelers handle everything from 0.012- to 0.312-in. sheet (though thickness capability depends on material type). "We put a lot of stress into the material," Kamins said, "but we have a way of taking that stress out."

"It takes a thick, U-shaped plate, even stainless steel, that looks like we never could use it," Beck said. "We send it through our CNC levelers, and it comes out perfectly flat."

This has allowed the company to tackle hole-making work that couldn't be done without subsequent leveling. The leveling also makes the punched blanks consistently flat for downstream forming and assembly, especially for the component work that flows through Accurate Metal Fabricating. 

QUANTITY CONSIDERATIONS

When it comes to making holes, it's hard to beat a perf press's productivity. "On each stroke, we can punch up to 1,600 holes," Kamins said. You can't do that using any other technology." "This is high-speed stamping," Beck said. "Our perf presses run at 300 strokes per minute."

Multiply this by the 18 perforating presses APC has on its floor, and you get a lot of hole-making capacity. With throughput like this, perforation presses thrive on high volumes. The CNC presses can perform skip feeds, leaving a section of the strip unperforated. Some tools can have block punches to make square or rectangular cutouts within a perf pattern. But for the most part, the process's sweet spot is consistent hole patterns.

High-volume hole-making goes to the perf presses; low-volume hole-making work goes to the turret punch presses—but what about the volumes in between? "For some applications, if we cluster-punched a job on a turret press, we wouldn't have enough time in the day," Beck said. "A job may call for 150 sheets, which would take about two hours on the turret press simply because of the number of holes. And we have just five turret presses." 

BRANDING WITH HOLES

Many OEM and POP customers have approached AP about a way to design their brand logos into a perforated sheet. AP employed programmers experienced in hole-intensive jobs on the turret punch press, and programming logo shapes, while intricate, was relatively easy for them.

As Kamins recalled, "After we did this, several clients came to us with a picture and asked, 'Can you punch this?'" Kamins added that the request evolved into a service AP now calls Picture-Perf, in which the company punches holes in a pattern that creates a logo, graphic, or picture.

"We saw similar things done differently before," said Beck. "So we asked, 'What if we use different-sized holes with different open areas and spaces between those holes?'"

The pattern can be small, in the corner of one panel on a POP display, or cover a building facade. For the new apartment complex in downtown Chicago, APC is providing 51 panels, each five by 13 ft., that, when assembled, depict a giant picture of the Greek Parthenon. 

PERF PRESS QDC

Years ago, every operator at Chicago-based Accurate Perforating changed out his press differently. Now, operators work under a standardized quick-die-change (QDC) process. Pit crews stage the tools before the previous run is finished and help the operator perform the changeover.

"We built tool cabinets so that all the tools needed for the operation sit right there," said Beck. "The operator no longer needs to walk two presses down and say, 'Hey! Johnny, I need a wrench.'" 

Want to save time, money, and the environment? Want to receive important order information automatically? Or support our Green Initiative by reducing the use of printed materials and carbon footprint by eliminating the transportation of documents? Well, now you can. Through enhanced electronic documentation from Accurate Metal Fabricating, your company can receive the following documents electronically and directly to the appropriate contact within your organization.

• Order Acknowledgements
• Shipping Acknowledgements
• Invoices

What is EDI?

Electronic Data Interchange (EDI) is a structured and standardized method for electronically exchanging business documents and information between organizations. It allows for the seamless and automated transfer of data, such as purchase orders, invoices, shipping notices, and other business-related documents, from one computer system to another. EDI replaces the need for paper-based communication and manual data entry, reducing errors and improving the efficiency of business processes.

Critical features of Electronic Data Interchange (EDI) include:

1. Standardization: EDI uses predefined data formats and communication protocols, ensuring consistency in data exchange between trading partners.
2. Automation: EDI systems automatically process incoming and outgoing documents, reducing the need for manual intervention.
3. Security: EDI systems typically use secure data transmission methods, such as encryption, to protect sensitive business information.
4. Cost savings: EDI can reduce administrative costs and processing times by eliminating paper-based processes and manual data entry.
5. Improved accuracy: Automated data exchange reduces the risk of errors in manual data entry.
6. Faster transactions: EDI enables more immediate document exchange, leading to quicker decision-making and improved supply chain efficiency.
7. Increased visibility: EDI provides real-time tracking and status updates for transactions, allowing organizations to monitor the progress of orders and shipments.

Interested To Chat Further on EDI?

You can specify the person or group of people who should receive each document. This will increase communication, speed up order processing, and reduce processing costs. Contact your project manager to learn more or sign up for Order Acknowledgement and Shipping Acknowledgement.

How Accurate Perforating collaborated with several other parties to bring an aspiring student's design concepts to life.

When Savanah began to develop her concept for the contest, she considered the number of people attending NeoCon and the issues that can occur with the overcrowding of spaces. Colestock explained, "My main focus was excellent circulation and to offer an open and airy space." The layout features meeting spaces via tall circular tables to facilitate discussions about the materials in the pavilion and provide an area of rest while navigating the massive show.

NeoCon 2017

Karrie Laughlin collaborated with Savanah to bring her design concept to life. Laughlin contacted numerous materials suppliers to support the initiative and settled on three very willing and capable companies, including Accurate Perforating & Metal Fabricating, to assist in the build.

Accurate worked with Karrie Laughlin, Wilsonart, and Panolite to engineer Colestock's designs. From the collaboration, Accurate and Wilsonart created a 72" long x 30" wide rectangular table designed to display material swatches at a convenient and pleasant height and angle. Accurate developed the table bases from 16ga. 1" carbon steel tubes cut, welded, ground, and then powder coated in soft gold. Wilsonart manufactured the tabletops from Calcutta Marble Solicor from .048" laminated on a ½" MDF board. The materials were joined together before Neocon 2017 by the Interiors + Sources staff.

Accurate and Wilsonart also worked together to create a 36" round wide circular table designed to provide Materials Pavilion attendees a space to converse and recuperate. Accurate made the table bases from 16ga. 1" carbon steel tubes that were cut, welded, ground, and then powder coated in soft gold. Wilsonart manufactured the tabletops from ½" Brooklyn Concrete 9219GS. Accurate also collaborated with composite panel manufacturer, Panolite, to build the large 72" H x 36" D x 11" W display towers essential in Colestock's design. Accurate constructed two-layered support bases of 1/8" carbon steel to prop up Panolite's unique presentation system. Accurate created the tower bases from 1/8" carbon steel plates that were cut, welded, ground, and powder coated in soft gold. Panolite manufactured the towers from a unique combination of ½" honeycomb cardboard core with surface board layers.

Commitment to Quality

With the commitment from Wilsonart, Panolite, and Accurate Perforating, Colestock's vision of a room with "good circulation and to offer a space that is open and airy" was brought to life.

When the Interiors + Sources magazine staff asked Accurate to design and build the display tables again for the Material Pavilion at NeoCon, we knew that we wanted to improve the functionality and design from the prior year and surpass their presentation requirements. After considerable discussion with Interiors + Sources, our engineers, and the design team, we decided on the following requirements:

• Display the products at an ideal level to encourage Pavilion visitors to view and touch the samples.
• Ability to ship the display tables nearly flat, quickly assemble onsite, disassemble at the end of the event, and reuse for the next several years
• Enhance the design of the tables so they are as appealing as the samples they are holding.
• Securely hold up to 300 lbs of weight per table

Engineering & Project Management

Once we determined the requirements for the 2018 NeoCon display tables, our design team, engineering department, estimators, and project management team collaborated to bring them to life.

• Design Team: We created the overall design of the display tables, choosing a cubist end-panel facade for a unique visual break.
• Engineering - Focused on the structural requirements of each table to ensure functionality and stability. 
• Project Management - Ensured the tables were made to the precise specifications and then packaged and shipped to arrive at Neocon 2018 on time and in perfect condition.

The end result was a reusable yet appealing display table that could show a large number of samples at an optimal height. Accurate can custom manufacture a display that fits your requirements, like a point-of-purchase display, merchandiser, or retail fixture. Come to us with just a concept or a fully developed product. We can work with you at any stage.

Capabilities used in manufacturing the NeoCon display tables

The display tables comprised seven distinct components designed to be assembled and quickly disassembled just with simple screws. Accurate utilized a wide range of capabilities to manufacture each component.

Flexibility in manufacturing merchandising and display components.

Accurate Perforating and its fabrication division, Accurate Metal Fabricating, has over 80 years of experience manufacturing custom point-of-purchase, merchandising, enclosures, and displays. We are aligned from project management and engineering to manufacturing and fulfillment to manufacture components for the retail and institutional industries.

Accurate Metal Fabricating corporate with Omni Ecosystem's producing parts for their Living Shelf needs. Our clients can use our experienced engineers, services, and sheet metal fabrication capabilities for prototypes and production parts. One of the projects we worked on together was for the new McDonald's corporation lobby in Chicago.

Living Wall With Sheet Metal

Green living walls are a trend in both interior and exterior design. Studies have found many health benefits of bringing a natural connection to the work environment. Your customer can also apply for higher green standard credits if they use Metal, which is fully recyclable.

Omni Ecosystem's Living Shelf was developed explicitly for interior edible plant applications, as they do have another product for interior non-edible planting (Omni Tapestry). Unlike most interior vertical planters on the market, Omni's Living Shelf has integrated lighting, irrigation, and ventilation systems to maintain optimal plant health. It was custom-designed and built for McDonald's new headquarters.

The parts Accurate made are the main planting shelves that support the potted plants, LED lights, ventilation pipes, irrigation lines, and unit drainage pan. Each unit contains two planting rows and is roughly 4 ft wide by 1 ft 8 in tall by 1 ft 8 in deep. They hang on a metal framework and a supplemental mechanical system, including the fans, transformers, and controllers. An overall drain pan underneath the entire assembly connects the system to the building's plumbing.

Shelving Components

Accurate fabricated the shelf components, including perforation, bending, welding, and anodizing. The pieces were assembled in Omni's warehouse, and the assembled units were installed onsite by Omni's subcontractors. Accurate provided matching brackets, end panels, and connector pieces that were installed onsite. Omni also worked with Accurate's engineering during the design process to help streamline the production. Accurate produced prototype units before the mass production of the 30 units that were ultimately installed onsite.

Accurate has fabricating equipment focusing on manufacturing products. It is a one-stop shop for a company looking to increase efficiency and reduce turnaround time. You can bring Accurate Metal Fabricating in at any point in the design stage, from adding existing parts to creating a new product line. We can also sign a non-disclosure agreement with the designer to protect their confidential information.

We Are Here To Fabricate Metal

Accurate Metal Fabricating is an expert at sheet metal fabrication products such as green walls, modular panels, and roofing. Contact us for more information today!
 

Having different types of welding in a metal fab shop is a give-in. If the metal fabrication shop you currently work with offers welding as a service, is it a metal fab shop? They might be, but welding is one of those "bread and butter" types of the fabrication process. But did you know that not all welding is the same? Different types of welding techniques and equipment are currently available. This two-part series will examine some of the more common weld techniques available at most fab shops, including ours. And then, we will come back to look at more advanced welding techniques in our next feature! Let's look at five different welding techniques you can use.

Stick welding

One of the earliest and most fundamental types of welding is stick welding, sometimes referred to as shielded metal arc welding (SMAW). It entails producing an arc with an electric current between a disposable electrode and the joined metal. The arc's heat melts metal, and a rod made of filler material welds the pieces together. Flux is applied to the rod, protecting the weld from the environment and possibly purging the metal of impurities. Stick welding is an easy and dependable technique. As the flux shields the weld from contamination, you find this type of welding typically in outdoor locations. It is also an excellent option for welding heavier metals because the flux can help improve a weld's penetration.

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MIG Welding

Metal inert gas welding is a common type of welding that uses a wire electrode and an inert gas to create the weld. It is a simple form of welding to master and is frequently used to join thin materials. In MIG welding, a continuous wire electrode is injected into the weld pool using a welding gun, and an electric arc melts it. The arc produces an electrical current and travels through the metal and the wire electrode. The substrate uses an inert gas, such as argon or helium, to protect itself from the atmosphere—the gas prevents oxygen and other airborne contaminants from contaminating the weld. MIG welding is a flexible and effective technique. Industries that use this technique include automotive, aerospace, and construction. Moreover, MIG welding is well-suited for thin gauge material and long, continuous welds.

Spot Welding 

Joins two or more metal sheets together using resistance welding. It exerts pressure and electrical current on the metal sheets, which heats them and causes them to melt where they come into contact. After cooling and solidifying, the molten metal forms a solid link between the sheets. The spot-welding procedure is quick. You will find spot welds in products such as cars and appliances. It works very well for welding thin metal sheets. The machinery concentrates pressure and heat on a tiny region, reducing the possibility of overheating or harming the metal. Spot welding involves clamping together one or more metal sheets and running an electrical current through them. At the point of contact, heat is generated when the current passes through the metal sheets and forms a resistance. This heat melts the metal, and as it cools, the molten metal solidifies, forging a solid bond between the sheets. The size and shape of the electrodes used to apply the current dictate the size and shape of the weld.

Robotic Welding

Robotic welding is a type of welding performed by a robot. A robot is used in an automated process to weld metal components. Compared to traditional welding processes, robotic welding offers several advantages. It fuses challenging parts for humans to reach and is faster and more accurate. Robotic welding significantly increases production efficiency by operating around the clock. This method eliminates many tedious welding processes. Heavy machinery, aircraft, and automotive industries frequently employ robotic welding.

TIG Welding

TIG welding is short for Tungsten Inert gas (TIG) welding. TIG is a more advanced form of welding that generates the weld using an inert tungsten electrode. You will find this technique when using thin materials requiring high-quality welds. A Tungsten electrode is utilized in TIG welding to generate an arc between the electrode and the metal itself. The arc's heat melts the metal, and the weld pool fills with filler material as necessary. An inert gas, such as argon or helium, protects the arc from the atmosphere. This gas aids in shielding the weld from contaminants. It may require more knowledge to perform TIG welding because it is a more complex process. It is often used for welding thin materials, such as sheet metal or tubing. In addition, welding ferrous and non-ferrous metals like aluminum and stainless steel utilize the TIG method.

Do you have a large project for which you need welding assistance? The experts at Accurate Metal Fab are here to help! We offer various metal fabrication options, including bending, forming, powder coating, and welding. Send us a quote and let us know how we can fabricate together.

Metal junction boxes are an essential electrical system component, serving as the central point for connecting and shielding electrical wires. Whether you're an electrician or an OEM, understanding junction boxes is crucial to knowing how your machinery is powered. This guide will explore everything you need to know about metal junction boxes, from their types and functions to installation tips and best practices.

What are junction boxes?

Junction boxes, also known as terminal boxes or conduit boxes, are enclosed containers that connect and protect electrical wires. They typically consist of a metal enclosure, a cover, and one or more knockouts or conduit entries for wiring. Depending on the electrical installation's needs, metal junction boxes are often installed on walls, ceilings, or floors. In addition, these enclosures supply electrical current to portable generators, among other things.

Are there several types of electrical boxes manufactured from metal?

• Electrical boxes: Made of sturdy metal, such as carbon steel, these boxes are suitable for outdoor and industrial applications, including HVAC units, portable generators, and large refrigerants.
• Waterproof junction boxes: These boxes, designed from aluminum to resist moisture, dust, and other environmental factors, are ideal for outdoor and wet locations.
• Explosion-proof electrical boxes: These heavy-duty boxes prevent the ignition of explosive gases, vapors, or dust. These boxes are essential for hazardous locations, such as chemical plants or refineries, and are designed not to fail even in extreme conditions.

What are the functions of conduit boxes?

Conduit boxes serve several critical functions in electrical installations, including:

• Connecting wires: Conduit boxes provide a central point for connecting wires from different circuits or devices, such as switches, outlets, or light fixtures.
• Protecting wires: Boxes are constructed to protect against damage, such as abrasion, impact, or accidental contact.
• Containing sparks: In case of a short circuit or electrical fault, a conduit box will have them and prevent further damage. This makes it safe for the essential workers in the field.
• Facilitating maintenance: Junction boxes allow easy access to electrical connections and wiring, making troubleshooting or repairing electrical problems a breeze.

How do you install terminal boxes?

Proper installation of terminal boxes is crucial for ensuring everyone is safe and that the metal box efficiently delivers the right power level to whatever it may be powering. Here are some tips and best practices for installing junction boxes:

1. Choose the right box type for your application based on the environment, load, and wire size.
2. Install the box at the right location, according to the electrical code and the installation's needs.
3. Securely mount the box using screws, anchors, or other fasteners, depending on the substrate.
4. Connect the wires correctly, following the wiring diagram and using wire nuts or other approved connectors.
5. Cover the box with the appropriate cover plate according to the type of box and the application's requirements.

Metal Is The Key To Electrifying Your World

Without metal, most of us could not efficiently power the world around us. That's why metal junction boxes are essential to any electrical system. They provide a safe and reliable way to connect electrical wires and protect them from individuals and the environment. Junction boxes crafted from metal are a critical part of any OEM application. At Accurate Metal Fab, we are here to partner with you to help you fabricate almost anything - including metal electrical boxes. Please feel free to reach out to us today for a free quote.

Powder coating advantages are numerous. It is a popular method of coating metal surfaces that starts with parts going through a multi-stage wash to ensure the surface is clean before applying paint. Then, a dry powder is electrostatically sprayed onto the surface either by highly-trained paint operators with paint guns or automatically with multiple spray nozzles to ensure every inch of metal is adequately coated. Then, the items are cured in an oven to create a durable and long-lasting finish. Finally, the material is spot-checked to ensure it has the proper coating. This multi-step process has multiple advantages for powder coating metal surfaces. This makes it the preferred choice over traditional liquid coatings for most metal forms. Let's look at five key advantages that powder coating offers for sheet metal and steel.

1. Durability

One of the most significant advantages of powder-coating metal surfaces is its durability. The powder coating creates a hard, resilient finish, often resistant to chipping, cracking, peeling, and fading. Several powders, including AAMA 2604 and 2605, further test the paint through multiple tests, including a salt spray, to ensure it will stand up to the elements.
 

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2. Versatility

Powder coating can be used to coat various metal surfaces, including steel, aluminum, brass, and copper. Depending on a customer's needs, a powder coating line can provide a range of colors, textures, and finishes, making it ideal for decorative and functional applications, including outdoor power equipment.

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3. Environmentally Friendly

The third advantage of powder coating is that it is more environmentally friendly than liquid paint. In fact, it produces no volatile organic compounds (VOCs) and generates little waste. The powder is continually recycled, going back and forth through tubes to ensure everything is recovered. Plus, the water that cleans every part is sent through large tanks that are recycled to maintain the proper chemical balance and purity needed to ensure each piece of steel is free of debris before being painted.

4. Cost-Effective

Another advantage that powder coating metal surfaces has is that it is a cost-effective process that can save time and money compared to traditional liquid coatings. The powder coating process is faster than liquid coating when applied to multiple parts. Parts are put on a powder line and go through a multi-stage approach. But the powder line is continuous, so you can place components (such as perforated steel) on it as needed, as long as the right color runs through the system for your particular application. And, of course, the finished product requires less maintenance and lasts longer, reducing the need for frequent recoating because of the high-level application process.

5. Consistency

Powder coating produces one of the most consistent finishes for metal and steel. Because of the multi-step process and quality control checks along the way, you can be sure your aluminum will be free from drips, runs, and sags. The electrostatic process ensures the powder is evenly distributed, resulting in a smooth and uniform finish.
 

BONUS! Ease of Maintenance

Powder-coated metal surfaces are easy to clean and maintain. The metal is resistant to scratches and stains and can be cleaned with mild soap and water.

These are just five (well, six) advantages of powder-coating metal surfaces, but there are many more. Its durability, versatility, environmental friendliness, cost-effectiveness, consistency, and ease of maintenance make it an ideal choice for various applications. Whether you are coating a small part of a large structure, powder coating can provide a long-lasting, attractive finish that will stand up to the elements and the test of time. Send Accurate Metal Fab a quote today on your powder coating needs.

We get many phone calls asking what can powder coat? And a way to review this is by welcoming everyone to the world of powder coating! Metal Fabrication companies, such as Accurate Metal Fab, transform metal and steel into stunning (and sometimes shimmery) parts that are complete with a durable finish. At Accurate Metal Fabrication, we are a premier sheet metal fabricator based in Chicago. We specialize in unleashing the potential of powder coating with our Powder Coating Paint Line. This blog post will explore what you can powder coat and its advantages.

1. Elevating Point of Purchase Displays: Powder coating has revolutionized the retail industry, enhancing and protecting metal and steel components. From a custom storefront to an experiential product launch, powder coating provides a resilient, high-quality finish that resists chips, scratches, and corrosion. While POP displays are often inside, the powder coating process allows these metal displays to be placed indoors and outdoors. Plus, as goods are placed on the shelves and taken off by customers, the durability of the powder will keep the display looking great for years. If you want a personalized and eye-catching look for your next POP display, powder coating will help.
2. Transforming Architectural Elements: Architectural structures are another application you can powder coat. Its features often benefit from the durability and aesthetic appeal of powder coating. From exterior cladding and perforated metal panels to restaurant partitions and signage, powder coating offers a seamless finish that withstands harsh weather conditions and extends the lifespan of metal and steel elements. Selecting powders and a coater, such as Accurate Metal Fab, which can offer AAMA 2604 and AAMA 2605 specifications, further allows for customization, enabling architects and designers to match specific colors and textures to their creative visions.
3. Boosting Metal Enclosures: What else can you powder coat? Why metal enclosures, of course! These are a specialty of many metal fabricators! Before powder coating, metal enclosures look just like a simple box. If you kept them in this raw state, they would be prone to rust much faster, and no one would take the enclosure seriously. These metal enclosures can often house critical electrical components for ATMs, parking garage kiosks, and more. Powder coating the enclosure helps boost its presence, stay on brand, and extend the machine's longevity.
4. Enhancing Industrial Equipment: Industrial equipment, such as screens and guards for the power generation industry, often faces extreme operating conditions and heavy wear. Powder coating provides an excellent solution for enhancing durability and prolonging the lifespan of machinery and components - especially outdoor equipment. From manufacturing machinery to storage racks and shelves, powder coating offers superior resistance to impact, chemicals, and UV rays, ensuring long-lasting protection.
5. Beautifying Outdoor Receptacles: An outdoor receptacle is another item you can powder coat. If you have a dog and have visited a doggie park, you've probably noticed the little trash areas to throw out your doggie's poop. Powder coating the receptacle enhances the structure's durability and looks great for a "messy" activity like trash cans. Powder coating also enhances other outdoor items in parks and recreation areas across North America. This includes playground structures, sports equipment, park benches, and bike racks. Using powder coating for these metal and steel products creates a vibrant, weather-resistant finish that can withstand the elements. The added protection ensures longevity, reducing maintenance costs and preserving the appearance of these essential assets.

Now That You Know What You Can Powder Coat – What's Next?

The applications of powder coating for metal and steel are virtually limitless. At Accurate Metal Fabrication, we have witnessed the transformative power of powder coating firsthand. Whether you're a retail designer, an architect, or an industry professional, powder coating is ideal for enhancing, protecting, and beautifying metal and steel surfaces. Embrace the possibilities and unlock the true potential of your projects with powder coating. Discover the full range of powder coating services offered by Accurate Metal Fabrication. Reach out today to discuss your project and experience our powder-coated finishes' exceptional quality and craftsmanship.

Sheet metal boxes are a fundamental component of industries worldwide, offering durability, customization, and cost-effectiveness. In this blog, we will explore the world of sheet metal boxes, their applications, benefits, and why Accurate Metal Fabrication is your go-to partner for all your sheet metal box needs in North America.

Understanding Sheet Metal Boxes

Sheet metal boxes are containers fabricated from sheets of metal, typically steel (hot rolled, cold rolled, or stainless) or aluminum. The type of metal used comes down to the specific application you'll need (which we will investigate below). Steel is cut or sheared to a specific size and width to form any enclosure, braked and formed to stringent tolerances, and welded to form a box-like structure. These boxes come in various shapes and sizes, making them highly versatile and suitable for various industry applications.

Various Applications of Sheet Metal Boxes

Steel is one of the most versatile substrates in the world. Because of this, it can be used in various applications - from perforated metal to steel tubes and sheet metal boxes. This article would go on for days if we explored every application. Instead, we will look at some of the highlights that steel enclosures are used. These include:

Industrial and Manufacturing: Metal is used in the industrial and manufacturing sectors to house electrical components, control panels, machinery, and more. Metal provides protection against environmental factors, ensures safety, and helps in an efficient organization. One example is Fresh Gear, a durable rapid sanitizing system that keeps PPE fresh and clean.

Electronics: Electronics manufacturers rely on sheet metal boxes for enclosures and chassis due to their ability to shield sensitive components from electromagnetic interference (EMI) and provide optimal heat dissipation.

Automotive: Sheet metal boxes are integral to the automotive industry, especially in the parts and services sectors. The enclosures carry the tools and parts needed to keep engines and other parts running. These metal cabinets are often made on wheels, giving them increased mobility for servicing your vehicle by trained technicians. Other automotive sheet metal box uses include enclosures for batteries, electronic systems, and engine compartments. They offer robust protection, ensuring the reliability and longevity of automotive components.

Data Centers: Metal Enclosures keep data centers moving across North America. They are used to house critical infrastructure that helps business technologies run. These sheet metal enclosures are designed with perforated metal panels necessary to ensure the proper airflow cools the hard drives and other technology that helps keep businesses up and running.

Receptacles: It's a dirty job, but something must do it! Whether for trash, medical purposes, or even animal poop, trash receptacles are a typical sheet metal box that we take for granted daily. They can be made to look like a simple box, one that locks (critical for medical waste) or more decorative for outdoor uses. Receptacles' most popular use is in the electrical industry. Electrical junction boxes provide critical power whenever you need it.

Weapon Racks: Universal weapon rack system provides maximal flexibility and accommodates the weapons you use now and in the future. Weapon racks for the military are modular so that they can accommodate various weapons of various sizes for secure storage.

Benefits of Sheet Metal Boxes

Durability and Strength: Sheet metal boxes are known for their exceptional durability and strength. The use of high-quality metal made in the USA, combined with precise fabrication techniques from a domestic metal fabricator, ensures that these boxes can withstand the demanding environments they are placed into and provide long-lasting performance.

Customization: Any enclosure can be tailor-made to meet specific customer requirements. With the ability to customize dimensions, cutouts, finishes, and features, there is always a solution in steel or aluminum that will fit your industry or application.

Cost-effectiveness: Sheet metal boxes offer cost-effective solutions compared to alternative materials like plastic or fiberglass. The efficient manufacturing process, ease of customization, and material recyclability make them an economical choice.

Recyclability: Metals, such as steel and aluminum, are infinitely recyclable, making them an excellent environmental choice. Other materials, like plastic or wood, don't offer a fully green choice when the box or enclosure has gone beyond the life of the sheet metal box.

Accurate Metal Fabrication: Your Trusted Partner

Accurate Metal Fabrication stands out as a reliable and experienced partner for sheet metal boxes. Headquartered in the suburbs of Chicago, we offer:

Expertise and Experience: With over 80 years of experience in metal fabrication, our skilled artisans, project managers, and engineers understand the unique requirements of different industries and deliver top-notch sheet metal boxes that exceed expectations.

State-of-the-Art Facility: Our production facility in Cicero, IL, has advanced equipment, including our 6KW Bystronic laser and a powder coating paint line. It enables us to provide precise, high-quality sheet metal boxes that meet the highest industry standards. Because of our centralized location, we have no problem bringing in raw materials or shipping to locations nationwide on a Just-in-Time basis.

Commitment to Customer Satisfaction: At Accurate Metal Fabrication, we prioritize customer satisfaction. We integrate with our clients, offering personalized support throughout the design and manufacturing process. This effort and detail ensure that the final product matches their needs. We don't stop there, as our project managers make it a point to build a relationship with everyone. We want to be your partner on today's job and every job you may have in the future.

Sheet metal boxes offer exceptional versatility, strength, and cost-effectiveness across various industries. Accurate Metal Fabrication's expertise, customization options, and commitment to quality make us the ideal partner for your enclosure requirements. Contact us today to discuss your project.