When it comes to building conveyor systems that actually deliver, the secret lies in the sheet metal. You can have the best motors and controls money can buy, but if your fabricated parts aren’t precision-crafted, your system will wear out faster than it runs.
Whether you’re building a high-speed modular conveyor or a rugged heavy-load system, poorly fabricated sheet metal components can create costly bottlenecks. So what separates a high-performance conveyor from one that’s always down for maintenance?
In this article, we’ll dive into 9 powerful sheet metal fabrication tips that will instantly improve the performance, durability, and efficiency of your conveyor systems. If you’re an engineer, project manager, or fabrication lead looking to improve your process, you’ll want to bookmark this page.
1. Choose the Right Material for the Job
Not all sheet metals are created equal. Stainless steel, aluminum, and carbon steel each bring different benefits. For example:
- Stainless steel resists corrosion and is ideal for food-grade or washdown environments.
- Aluminum is lightweight and great for reducing overall conveyor load.
- Carbon steel is cost-effective and ideal for non-corrosive environments.
Pro Tip: Always match the metal type to the specific load, speed, and environmental conditions of your conveyor system.
2. Precision Matters: Invest in Laser Cutting
Laser cutting offers unmatched precision for conveyor components. Tolerances as tight as ±0.005″ can make a huge difference in wear and vibration.
When your conveyor’s parts are cut accurately, you:
- Minimize friction
- Improve alignment
- Reduce vibration
It’s a small investment upfront that pays off big in reduced downtime.
3. Weld for Strength—Not Just Speed
Quick welds might save time today, but poor joint integrity will cost you dearly later. For conveyor systems, prioritize MIG or TIG welding depending on the material and load capacity.
FAQ: “What kind of weld is best for high-speed conveyors?”
TIG welding is typically better for aluminum or thinner materials, while MIG works well for thicker, structural components.
4. Don’t Overlook Bends and Tolerances
Incorrect bends or inconsistent tolerances cause misalignments that wreck performance. A conveyor frame that’s off by just 1° can cause constant belt tracking issues.
Solution: Use CNC press brakes and consistent bending practices. Every bend should be engineered and checked for deviation before moving to assembly.
5. Surface Finishing: It’s More Than Cosmetic
A rough or unfinished surface can lead to product snags, increased friction, and even injuries.
Consider finishing options like:
- Deburring to remove sharp edges
- Powder coating for corrosion resistance
- Brushed finishes for smooth, food-safe conveyors
Stat to Know: A smoother surface can reduce energy use by up to 10% due to lower drag.
6. Think Modularity From Day One
Want easier repairs and less downtime? Build conveyors with modular sheet metal parts. That way, individual panels or guards can be replaced without removing the entire assembly.
Bonus: Modular designs are easier to upgrade in the future.
7. Use Gussets and Reinforcements Wisely
Undersupported frames sag. Sagging leads to roller misalignment. Roller misalignment leads to belt drift—and that’s how your conveyor becomes a money pit.
Use gussets or reinforcing ribs in high-stress areas, especially near bends, joints, and support brackets.
8. Consider Vibration Damping in Design
Sheet metal isn’t naturally vibration-resistant. In high-speed conveyor systems, vibration can shorten motor life and increase maintenance costs.
Tip: Incorporate dampening mounts, or use composite sheet materials with vibration-dampening properties.
9. Don’t Skip the Quality Check
Before final assembly, inspect each fabricated component for:
- Material defects
- Dimensional accuracy
- Surface finish
- Hole alignment
Remember: Every misaligned hole becomes a misaligned roller—and every misaligned roller becomes a service call.
Conclusion:
Building high-performance conveyors starts with getting the sheet metal fabrication process right—period. The best systems aren’t always the most expensive; they’re the most precisely built. Whether you’re customizing for food, pharma, packaging, or industrial applications, applying the tips above will drastically improve uptime, performance, and customer satisfaction.
Don’t let cheap fabrication slow you down. Use these insights, work smarter, and keep your conveyors running lean and clean.
MATERIAL HANDLING TECHNIQUES, INC.is your professional custom fabrication and material handling for Michigan and all surrounding areas. If you are interested in any of our services, please reach out to us at Your # today!