Reducing Fabrication Costs with Material Selection

Want to cut fabrication costs by up to 20%? The key lies in choosing the right materials. While opting for cheaper materials might seem logical, it often leads to higher machining times, tool wear, and additional processing steps - ultimately increasing overall expenses. Instead, focus on balancing upfront costs with long-term savings by considering factors like machinability, waste reduction, and compatibility with your equipment.

Key Takeaways:

• Material choice affects every cost factor: from raw material prices to machining time, tool wear, and waste.

• Balance initial and lifecycle costs: Premium materials like Aluminium 6061 or Brass C360 may cost more upfront but save time and reduce tool wear in production.

• Design for efficiency: Simplify geometries, use standard sizes, and optimise layouts to minimise waste and machining time.

• Source locally when possible: UK-based suppliers can reduce shipping costs, lead times, and administrative burdens.

MASTERS OF ENGINEERING | Cost-Effective Design - Sheet Metal

How Material Selection Affects Fabrication Costs

When planning a fabrication project, the material you choose impacts every cost factor - from the initial purchase to production. It's not just about the raw material price; machining behaviour, tool wear, and waste output all play a role in determining the overall financial impact.

Material selection directly influences CNC machining costs, affecting raw material expenses, processing time, tooling needs, and waste generation. For example, softer materials like aluminium are easier to machine, resulting in reduced cutting forces, lower tool wear, and shorter production times. This means faster machine cycles, tools that last longer, and lower labour costs.

The best material for a project is one that meets the necessary specifications while keeping overall costs in check. Sometimes, a material that seems expensive at first can save money in the long run through faster machining and fewer tool replacements. Conversely, a cheaper material might lead to higher costs due to longer machining times and frequent tool changes. This balance between material costs and manufacturing efficiency is key to understanding total lifecycle expenses.

Initial Costs vs Lifecycle Costs

Balancing upfront material costs with long-term production expenses is a critical decision in fabrication. Initial costs refer to the price of raw materials, while lifecycle costs encompass machining time, tool wear, waste, post-processing, and material durability.

Take polymers, for instance. While some options are cheaper upfront, they may require longer machining times and cause higher tool wear, leading to increased lifecycle expenses. Metals follow a similar principle. For example, carbon steel with zinc plating can provide corrosion resistance similar to stainless steel but at a lower cost. If your project doesn’t demand the full corrosion resistance of stainless steel, this substitution can save money without sacrificing performance. Similarly, when high strength isn’t essential, aluminium can be a cost-effective alternative to titanium, offering sufficient durability at a lower price.

Premium materials with better machinability, such as 303 stainless steel and C360 brass, might have higher upfront costs, but they can significantly reduce machining time and tool wear, especially in high-volume production runs. For smaller orders or prototypes, prioritising lower raw material costs makes sense, as machining time is less critical. This approach helps optimise the total cost of ownership rather than just focusing on initial expenses.

Material Properties and Manufacturing Compatibility

Material properties heavily influence both fabrication costs and production timelines. Machinability - how easily a material can be cut and shaped - is a major factor. Choosing a material isn’t just about buying the raw stock; it’s also about how efficiently your machines will run and how long your tools will last.

Materials like aluminium are easier to machine, which lowers processing costs compared to harder materials like stainless steel or titanium. Aluminium requires less cutting force, allowing CNC machines to operate at higher speeds with less strain on tools and spindles. This translates to faster production cycles, lower energy use, and reduced tool wear. On the other hand, harder materials like stainless steel and titanium wear out tools faster, require specialised cutting equipment, and lead to more frequent tool changes and downtime - all of which drive up costs.

Some materials may also demand advanced CNC capabilities, such as a 5-axis machine instead of a 3-axis, which can significantly increase fabrication costs. High-machinability materials like Brass C36000 and Aluminium 6061 reduce machining time, minimise tool wear, and speed up production cycles. Their consistent performance also cuts down on quality control time and rejects.

Waste generation is another consideration. Opting for materials available in standard sizes and consistent quality reduces the need for custom preparation, which helps lower costs. For specialised applications - like marine or chemical environments - materials such as stainless steel, titanium, or certain plastics provide essential corrosion resistance but come at a higher price. It’s important to assess whether these premium properties are truly necessary, as over-specifying materials can unnecessarily inflate costs.

When selecting materials, factor in not just the raw material price but also compatibility with your machinery and the expected tool wear. Aligning material properties with your manufacturing capabilities can make a significant difference in achieving long-term cost savings.

Methods for Reducing Fabrication Costs Through Material Selection

Understanding how materials impact your costs is only the first step. The real challenge lies in applying practical strategies to make smarter choices that align with your manufacturing capabilities, all while maintaining the quality your projects demand. Here's how you can make it happen.

Select Materials That Match Your Manufacturing Processes

Choosing materials that work seamlessly with your equipment is a straightforward way to lower fabrication costs. When your material selection aligns with your machinery's capabilities, you can minimise setup time, reduce tooling expenses, and avoid unnecessary complications.

For instance, high-efficiency five-axis CNC machines can handle tougher metals, but if your workshop primarily uses three-axis machines, materials like aluminium 6061 or brass C360 are far more practical. These softer materials allow for faster machining, reduced cutting forces, and longer tool life - all of which bring down costs per part.

On the flip side, using materials that exceed your equipment's capabilities can lead to outsourcing or investing in specialised tooling, both of which drive up expenses. Instead, focus on materials that your current setup can handle efficiently. For example, in sheet metal fabrication, matching material thickness and type to your bending and cutting equipment helps prevent issues like cracking, excessive wear on tools, or dimensional inaccuracies.

Consider Material Substitution

Swapping out expensive materials for more economical alternatives that still meet your performance needs is another effective way to cut costs. The idea is simple: use the least expensive material that gets the job done.

For example, if corrosion resistance isn’t critical, carbon steel with zinc plating offers a cheaper alternative. Similarly, when high strength isn’t essential, aluminium can replace titanium, offering adequate durability at a fraction of the cost. For non-structural parts, softer metals or even polymers can often replace harder materials without sacrificing functionality.

The key is to avoid over-specifying materials. Many projects default to premium options out of caution, but a detailed assessment often reveals that less costly alternatives work just as well. For instance, if you need wear resistance but not the full hardness of tool steel, alloy steels or surface treatments on softer materials might suffice. Collaboration between design and manufacturing teams is crucial here to identify where substitutions make sense without introducing unnecessary risks.

Once you’ve identified cost-effective alternatives, standardising these choices across your operations can amplify the savings.

Standardise Material Choices Across Product Lines

Using the same materials across multiple products can lead to significant savings through economies of scale. When you standardise materials, you simplify inventory management, reduce storage complexity, and minimise the risk of holding obsolete stock.

Beyond material savings, standardisation streamlines manufacturing. Fewer material types mean less coordination across your supply chain, and machinists become more efficient as they gain familiarity with the same materials. Quality control also benefits, as inspectors know exactly what to expect, reducing errors and inconsistencies.

Relying on widely available materials and off-the-shelf components can even bring the cost advantages of mass production to small-batch runs. To implement this strategy, audit your product range and look for opportunities to consolidate materials. Often, you’ll find that switching to a single material doesn’t compromise performance but significantly reduces costs.

Design for Material Efficiency

Efficient design is one of the most impactful ways to reduce material waste and, by extension, production costs. By optimising your designs, you can cut waste before production even begins.

Take sheet metal fabrication, for example. Nesting optimisation, or arranging parts strategically on raw material, reduces scrap and maximises the usable area of each sheet. This not only lowers material costs but also cuts waste disposal expenses.

Simplifying part geometry is another cost-saving measure. Features like sharp internal corners require specialised tools and multiple passes, which increase machining time. Opting for radiused corners, which can be cut in a single operation, saves both time and money. Similarly, removing unnecessary features - like extra holes, slots, or threads - streamlines production without affecting functionality.

Using standard tool sizes and tolerances also helps. Designs that accommodate common drill sizes, thread pitches, and end mill diameters eliminate the need for custom tools, reducing machining time and costs. Additionally, relaxing tolerances wherever possible can cut cycle times and avoid secondary finishing operations, which are often expensive and time-consuming.

Modern CAD tools and simulations can further refine your designs. By testing material layouts, cutting strategies, and design variations virtually, you can identify inefficiencies and optimise processes before production starts. These tools help you avoid costly mistakes and ensure that your designs make the most of the materials you’re using.

The Benefits of Local Material Sourcing

Choosing UK-based suppliers for material sourcing offers more than just convenience - it’s a smart move that can trim fabrication costs and streamline operations. By going local, businesses can sidestep many of the hidden expenses and challenges tied to international procurement, all while improving supply chain efficiency.

One of the biggest advantages is the elimination of international shipping fees, customs duties, and logistics costs. For smaller to mid-sized fabrication projects, these savings can add up quickly, often reducing total material acquisition costs by 10–15%. This is especially true for heavy or bulky materials, like sheet metal, where transportation costs can be a significant factor.

Local sourcing also brings flexibility to production scheduling. With UK-based suppliers, lead times are much shorter, making just-in-time manufacturing a practical option. Instead of holding large inventories to compensate for long international shipping times, materials can be ordered as needed and delivered within days. This approach reduces warehousing costs, frees up working capital, and lowers the risk of material obsolescence.

Another key benefit is compliance. Materials sourced from UK and European suppliers typically come with the necessary certifications and documentation to meet UK standards. This eliminates the need for extra testing or third-party verification, cutting down on administrative costs and avoiding potential rework. The traceability and compliance records provided by local suppliers simplify the process significantly.

Local sourcing also lightens the load on your supply chain. Without the added complexity of intermediaries, customs brokers, and international freight handling, the administrative and logistical burdens are reduced. This streamlined approach saves both time and money.

Additionally, local suppliers are better equipped to handle urgent requests or mid-project changes. If a material specification needs tweaking, resolving it locally minimises delays and keeps production on track. Face-to-face communication and in-person technical discussions further enhance collaboration, which can be harder to achieve with overseas suppliers.

The environmental benefits of local sourcing are another compelling factor. Shorter transportation distances mean lower fuel usage and reduced carbon emissions. As UK businesses face increasing pressure to meet environmental goals and prepare for potential carbon taxes, sourcing locally not only supports sustainability but also makes financial sense. For instance, with the UK recycling about 47% of processed steel, recycled materials are more readily available, contributing to long-term cost savings.

For widely used materials like Aluminium 6061, Stainless Steel 303, and Brass C360, the UK supply chain offers competitive pricing, short lead times, and consistent quality. These materials are easy to machine, making them ideal for standard fabrication projects. By standardising on locally sourced materials, businesses can simplify procurement, maintain consistent quality, and build strong supplier relationships.

When evaluating costs, it’s important to look beyond the purchase price. Factors like transportation, lead times, inventory costs, and quality assurance all play a role. Considering the total cost of ownership, local sourcing often proves to be the more economical choice, typically saving 10–20% compared to international options for standard materials.

A hybrid approach can be effective: rely on local suppliers for high-volume, standard materials, and turn to international sources only when specialised materials are needed. This way, businesses can enjoy the cost savings and operational benefits of local sourcing while still meeting specific performance requirements for unique projects.

Measuring and Monitoring Cost Savings

To confirm cost savings from material choices, start by comparing results against a baseline. Establish this baseline by documenting current material costs, machining times, scrap rates, and tool replacement frequency over three production cycles. This ensures you account for normal variations and have a reliable starting point for comparisons.

Key Metrics for Success

Several metrics can help determine if your material selection is cutting costs. One of the most important is material waste percentage. Calculate this by dividing the scrap weight by the total material weight used, then multiply by 100. For instance, if a business uses 10,000 kg of material annually at £15 per kg, reducing waste from 15% to 8% results in an annual saving of £10,500.

Another critical metric is machining time per unit, as it directly impacts labour costs. Materials like Aluminium 6061 and Brass C360 are easier to machine, significantly reducing machining time compared to harder materials like stainless steel or titanium. For example, with a £50 per hour labour rate, cutting machining time from 4 hours to 2.5 hours per unit saves £75 per unit - or £37,500 across a 500-unit production run.

Tool wear rates also need attention. Monitor how many parts are produced before tools need replacing to evaluate whether more machinable materials are reducing wear and tear.

The ratio of material cost to total fabrication cost is another valuable indicator. If material costs make up 40% of total expenses, optimising material selection could lead to considerable savings. On the other hand, if materials only account for 15% of costs, focusing on machining efficiency might yield better results.

Additionally, track cost per unit, which includes material, labour, tooling, and post-processing. This metric ensures that savings in one area aren’t offset by unexpected increases elsewhere. For instance, a cheaper material might require costly finishing work, negating the initial savings.

Lead times and inventory turnover rates are also crucial. Choosing readily available materials in standard sizes can reduce procurement delays and storage costs. For example, cutting inventory from six weeks to two weeks frees up working capital and reduces storage expenses, improving overall profitability.

These metrics provide a solid foundation for assessing the financial impact of your material choices.

Using ROI to Evaluate Material Decisions

Once you’ve gathered data, calculate the return on investment (ROI) to measure the overall impact of material changes. The formula is simple: (Total Savings - Implementation Costs) ÷ Implementation Costs × 100%.

When switching materials, total savings should account for reductions in raw material costs, machining time, tool wear, and post-processing expenses. Implementation costs typically include design updates, tooling adjustments, and staff training.

For example, switching from titanium to Aluminium 6061 might save £500 per unit in material costs and £100 per unit in labour, totalling £600 in savings per unit. For a production run of 1,000 units, this adds up to £600,000 annually. If implementation costs are £15,000, the ROI would be: (£600,000 - £15,000) ÷ £15,000 × 100% = 3,900%. That’s a compelling reason to make the change.

However, ROI isn’t just about immediate savings. Consider the total cost of ownership over the product’s lifecycle. This includes raw material costs, machining labour, tool wear, energy use, finishing, waste, inventory costs, and long-term durability or maintenance.

For instance, compare stainless steel to carbon steel with zinc plating. Stainless steel might cost £20 per kg and take 3 hours to machine, while carbon steel costs £8 per kg and takes 2 hours. If corrosion resistance isn’t essential, carbon steel with zinc plating offers similar performance at a lower overall cost.

To make decisions easier, create a comparison matrix listing each material's costs across all categories. This allows for an objective evaluation of which material offers the best value. In high-volume production, materials with higher upfront costs but better machinability - like Brass C360 - can ultimately result in lower total costs than harder-to-machine alternatives.

Volume discounts also play a role. Bulk orders can significantly lower per-unit costs, so factor in your typical order sizes when comparing materials. Be sure to update calculations quarterly to reflect current material prices and production volumes.

Indirect benefits should also be included in your ROI analysis. These might include improved cash flow from faster production cycles, reduced inventory holding costs, and increased competitiveness through lower pricing.

Using tracking software to monitor machining start and end times can provide precise data for comparing new material choices against historical benchmarks. This helps identify whether the expected improvements are being achieved and highlights areas for further optimisation.

Some organisations are even leveraging AI-assisted generative design to achieve material savings of up to 20% by identifying ways to use less material while maintaining structural integrity. This shows the potential for significant cost reductions through systematic material optimisation.

Conclusion

Choosing the right materials is a smart way to keep fabrication costs in check without compromising on quality or performance. The aim is to find materials that offer the best balance of total lifecycle costs, factoring in raw materials, processing, and service expenses.

Thoughtful material selection can make a big difference. For instance, in low-volume production, aluminium 6061 stands out for its affordability and ease of machining, making it a great choice for prototypes and small batches. On the other hand, when production ramps up, materials like brass C360 or stainless steel 303 - despite their higher raw material costs - can save money in the long run due to faster machining times and reduced labour costs. This highlights the importance of considering both initial costs and long-term efficiency.

The most cost-effective material is one that meets the technical requirements of your part while minimising overall costs throughout its lifecycle. For example, premium materials like PEEK, which can cost around £210 per kilogramme, are best reserved for applications where their unique properties are essential. Meanwhile, softer and more common materials often reduce tooling expenses and machining time compared to harder, less common options.

Streamlining both material selection and manufacturing processes is equally important. Modern techniques like AI-assisted generative design are helping businesses reduce costs by optimising designs to use less material. Opting for materials with high machinability simplifies production, cutting down on machine setup times and the number of operations required - leading to further savings. By matching material properties to manufacturing needs, you can unlock significant cost benefits.

Collaboration also plays a key role. Working closely with fabrication partners who understand the interplay between material properties and manufacturing processes can lead to quicker, more practical decisions. In the UK, companies like Framos Fabrications provide a full range of services - from CAD design and CNC laser cutting to bending and welding - making it easier to achieve efficient, tailored solutions. Building such partnerships not only streamlines production but also supports sustainable and cost-effective practices.

Although premium materials may come with higher upfront costs, they can offer long-term advantages like reduced machining time, lower scrap rates, and better recyclability - factors that could help offset future expenses for raw materials.

FAQs

How does using locally sourced materials help reduce costs and improve efficiency in fabrication projects?

Choosing locally sourced materials can make a big difference in cutting costs and boosting efficiency. When materials come from nearby, transport expenses drop, lead times shrink, and the chances of shipping or customs-related delays decrease significantly.

Another advantage is that local materials often align with regional standards and specifications. This means they’re more likely to meet your project’s needs without extra adjustments, making the fabrication process smoother. The result? Consistent quality and savings in both time and money over the course of your project.

What benefits do premium materials like Aluminium 6061 and Brass C360 offer for high-volume production?

Premium materials like Aluminium 6061 and Brass C360 are excellent choices for high-volume production, thanks to their distinct characteristics that boost efficiency and product quality. Aluminium 6061 stands out for its impressive strength-to-weight ratio, resistance to corrosion, and ease of machining, making it perfect for creating lightweight yet sturdy components. Meanwhile, Brass C360 is known for its outstanding machinability and wear resistance, ensuring precise, reliable parts while minimising tool wear.

Incorporating these materials into production can lower fabrication costs by speeding up manufacturing processes, reducing material waste, and prolonging tool life - key factors for keeping large-scale projects cost-effective.

How can businesses balance material costs with long-term savings in fabrication projects?

Choosing the right materials for fabrication projects is all about finding the sweet spot between upfront costs and long-term value. While some materials might seem pricey at first glance, they often come with perks like better durability, lower maintenance needs, and longer lifespans - factors that can save you money in the long run.

When making your decision, think about key aspects like the material's strength, its ability to resist wear and corrosion, and how well it suits your specific project. For instance, stainless steel may cost more initially, but its durability and minimal upkeep can make it a cost-effective choice over time. Partnering with an experienced fabrication expert, such as Framos Fabrications, can provide you with the insights needed to pick materials that fit both your budget and project requirements.

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