Alternatives to Welding for Joining Laser Cut Metal

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You have a project that needs laser-cut metal parts…but welding isn’t your thing. How should you assemble metal parts without welding?

Laser-cutting to the rescue

Laser-cutting is faster and more accurate than waterjet, so you upload your drawing to the SendCutSend website and sort through the available metals there.

There’s just one problem: You can’t weld worth a darn. We all have our gifts, and try as you might, this one isn’t part of your skillset. Besides, even if you were a good welder, you can’t afford the equipment. That’s okay. You’re nothing if not resourceful. You begin assessing available alternatives:

Two-part epoxy

Glue might sound like a silly choice for fastening metal parts, but good epoxy is amazing stuff. In fact, cosmonauts used a bit of glue and cloth to fix a hole in the Soyuz MS-09 spacecraft as it docked with the International Space station in 2018. Provided you clean the surfaces with acetone or mineral spirits, roughen them up a bit with some sandpaper, and then etch the aluminum with a little citric acid immediately before assembly, a good two-part epoxy is all you need.

Copper pipe fittings and copper epoxy joining compound


Another great alternative is rivets. If they’re good enough for airplanes, they’re good enough for just about anything. They’re inexpensive, easy to install, and if you make a mistake or break a rivet, simply drill it out and install another. If you thought ahead, you would have drawn some rivet holes in your CAD file before uploading it to SendCutSend’s online instant quoting tool, but drilling them by hand is a simple task. You’ll need to order a rivet gun, however (about twenty bucks on Amazon), along with the correct type and length of rivet. A general guideline is one-and-a-half times the combined material thickness, and aluminum parts require aluminum rivets, steel needs steel, and so on. Again, no big deal.

Silver blind rivet Screw Rivets for hand riveters

Brazing and soldering

Though similar to welding, neither of these joining methods call for expensive equipment, nor the skills needed to “lay down a bead” of molten metal. They do require a gas torch, some flux (a chemical compound), and the correct filler metal, but brazing or soldering two laser-cut parts together is no more difficult than installing a kitchen faucet.

soldering iron soldering wire isolated on white background

So what’s the difference? Soldering is performed with filler metals that melt at 450°C (842°F) or below, while those used with brazing melt above this temperature. That makes brazed joints more robust than soldered ones, but either is quite suitable most projects. As with epoxy, the parts must be thoroughly cleaned before joining, although the flux used in either process serves to remove any of the oxidization that occurs on bare aluminum surfaces.

Who needs welders?

Other joining methods exist. Nuts and bolts are one option, although a bit bulky for some applications. Sheet metal screws eliminate the need for a mating nut, but generally require that holes be threaded before assembly (thin-gage aluminum can be joined with self-tapping screws). There’s also spot welding. This is simple enough for the proverbial caveman, although it does need special welding equipment (you guessed it—a spot welder).

If you aren’t a welder, but still need to stick some metal together, a bit of epoxy or rivets will help you get the job done.

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We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Zinc plus Clear Chromate

Aluminum: 5052, 6061, 7075 Steel: Mild, G30

Thread Size4-40 x .250″
Hole size in sheet (+0.003/-.0.000).168″
Minimum sheet thickness0.040″
Maximum sheet thickness.125″
Fastener materialSteel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole..345″
Recommended panel materialSteel/Aluminum
Coating typeZinc
Aluminum material ranges (5052, 6061, 7075)0.040″-0.125″
Steel material ranges (CRS, HRPO, HR)0.048″-0.119″

We proudly use hardware by PEM

Flush Standoff, 4-40, .250" Passivated

Stainless Steel: 304, 316

Thread Size440
Hole size in sheet (+0.003/-.0.000).166″
Minimum sheet thickness0.04″
Maximum sheet thickness.125″
Fastener material400 Stainless Steel
Minimum distance hole C/L to edge0.230″
When determining the distance between two or more fasteners, you can calculate the distance by the formula, C/L to edge + 1/2 the diameter of the second mounting hole. Example shown with x2 of the same hardware..313″
Recommended panel materialStainless Steel
Coating typePassivated
304 Stainless Steel material ranges0.048″-0.125″
316 Stainless Steel material ranges0.060″-0.125″