Sheet Metal Welding Services

3 Materials

.060"-.250"

+1-2 days

Production Time

Welding sizing and options

Part Sizes

.375" x 1.5"

Min part size

30" x 44"

Max part size

3 MATERIALS, .060" - .250"

5052 H32 AluminumMild Steel304 Stainless Steel

Compatible Services

Laser cuttingBendingCountersinkingDimple FormingTappingDeburringAnodizingPowder Coating

Fast turnarounds to keep your projects moving

SendCutSend offers welding services on flat sheet metal parts that have been bent.

Simplified design & ordering

We automatically handle weld compensation and joint normalization.

MIG, TIG & laser welding

We determine the most suitable weld type and style ensuring the best quality welds.

Fast and reliable lead times

Standard welding orders ship in 2-4 days from time of order.

“Everytime SendCutSend nails my design and delivers my inception almost faster than I could do it if I had the tooling personally available.”

Jacob Karns

Available materials for Welding

Our welding services are compatible with several metals and thicknesses.

For a full list of materials and available thicknesses, please visit our materials page.

One step to a finished part
Built to take abuse
Looks as good as it performs

5052 H32 Aluminum

7 thicknesses: .063" – .250"

Mild Steel

6 thicknesses: .074" – .250"

304 Stainless Steel

4 thicknesses: .060" – .125"

Upload now for instant pricing

Welding adds 2-4 days to production. For the fastest lead times, order welded parts separately.

Affordable pricing. Up to 70% off in bulk.

5052 H32 Aluminum .063"

3.816 x 4.865 in

Laser cutting, bending, deburring, welding

Qty 1:

$55.62/ea

Qty 100:

$8.37/ea

5052 H32 Aluminum .080"

10.07 x 8.609 in

Laser cutting, bending, deburring, welding

Qty 1:

$75.00/ea

Qty 100:

$13.78/ea

5052 H32 Aluminum .125"

8.166 x 7.206 in

Laser cutting, bending, deburring. countersinking, welding, anodizing

Qty 1:

$92.67/ea

Qty 100:

$32.05/ea

Design guidelines for welded parts

Following a few basic design guidelines will help ensure your parts are welded properly and pass SendCutSend review.

Sizing & hole requirements

Sizing limits apply to flat parts before bending

Min part size (flat)	.375″ x 1.5″
Max part size (flat)	30″ x 44″
Thickness range	.060″ – .125″
Max root gap	.020″
Min root gap	None (as long as the part bends without flange collision)

The root gap is the space between the two material faces the weld needs to fill. Our absolute process limit is .030″, but the .020″ max accounts for bending tolerances.
You can measure root gap in Fusion 360 or a viewer like eDrawings.
Verify thicknesses and grades in the Material Catalog.

Weld types we offer

Corner weld: Two flanges meeting at a 90° corner.
T-joint weld: A corner weld with an extended flange on the side.

Both can be applied to the inside (concave) or outside (convex) of the joint. For corner welds, the outside gives better material coverage. For t-joints, either works well.

Not currently offered: butt, lap, spot, stitch, continuous/fusion, or multi-part assembly welds.

Design considerations

Design for bending first: Parts must be ordered with bending applied. See Bending Guidelines.
Don’t model weld features: Don’t model fillets, weld beads, or any weld geometry. Model the bent part as you want it made; we handle the rest.
Bend seams aren’t sealed: We don’t fill or seal bend relief gaps or open bend seams.

What to expect with welded parts

Hand-guided process: Welding is done by hand, prioritized for strength and function over cosmetics.
Pulse texture: Pulse welding produces a “stack of dimes” texture along the bead. This is normal and not smoothed (grinding coming soon).
Weld variance: Up to .1″ deviation from the weld baseline is possible.
Weld throat thickness: Typically ~1/16″ on thinner materials, ~1/8″ on thicker materials.
Tack welds: May be used to hold the part in position. They won’t be visibly raised on the finished weld.
Low heat-affected zone: Laser welding minimizes warping compared to MIG or TIG.
Sharp edges remain: Edges at and around the weld are not softened unless specified.
Not watertight or gas-tight: We can’t guarantee sealed welds.
No certified welds: We don’t provide weld inspection reports or certifications.
SendCutSend parts only: We can’t accept outside parts for welding. Parts must be ordered through SendCutSend.

Additional welding resources

If you’re designing parts for welding, these resources may help:

Pre-flight checklist

File is in a format that we accept (2D: .dxf, .dwg, .ai, .eps; 3D: .step or .stp)
All holes and cutouts are at least 50% material thickness for laser cut parts
All holes and cutouts are no less than 0.070” for most waterjet cut parts
All holes and cutouts are no less than 0.125” for all CNC routed parts
File is built at a 1:1 scale, preferably in inch or mm units
2D files: all objects on the same layer, text converted to outlines, no open contours, all shapes united or merged, floating interiors bridged or stencilized
3D files: single solid sheet metal body, uniform thickness with a face at every edge, modeled at stock thickness with matching bend specs
All stray points, duplicate lines, empty objects and text areas have been removed

SendCutSend reviews

Customers love getting their sheet metal parts from us

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   Jeff S 
 September 23, 2026.
 
 
  Exceptional service and very fast turnaround.  Super easy to use website and the results are top quality
  
 
      Posted on Google  
   
   Nathan Raper 
 September 23, 2026.
 
 
  I ran into an issue replacing an old sink and needed a stainless steel spacer.  SendCutSend was amazing!  Awesome AI Tool to help me design exactly what was needed, round the edges to match my sink and get the order placed!  Very reasonable pricing and about a week and a half later, I had my spacer!  Will definitely use them again!
  
 
      Posted on Google  
   
   MIKE ROB 
 September 23, 2026.
 
 
  What a great company, website is easy as can be, part was machined perfectly, every step of the process was updated VIA text and part was shipped and delivered days ahead of schedule at a price that can't be beat. I work in R&D at a company with 50+ CNC machines and prefer to use these guys because our machines are all running production programs and down time to do one-offs is a hassle. Send Cut Send is a true resource that even well equipped shops can benefit by using them.
  
 
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   Chris B 
 September 23, 2026.
 
 
  Needed some custom panels for my audio build and was running out of ideas so went to their website and used their templates and made the panels i needed to my measurements and a few days later they arrived. They were just how i wanted. Will be using them again in the future.
  
 
      Posted on Google  
   
   Chris M 
 September 23, 2026.
 
 
  Laser focused.
  
 
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   Robert Flaterås 
 September 22, 2026.
 
 
  First time experience with SCS and they deliver excellence. Sent over dxf file of vintage carburator spacer suited for my 1947 Studebaker M15A. Selected the 1/2" G10 fiberglas isolator and pressed go. Rapid service and dispatch. Got the final product delivered to Norway and same day installed with perfect results. Very happy customer!
  
 
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   Todd Clark 
 September 17, 2026.
 
 
  Great quality parts, reasonably priced & fast service.  Highly recommend!
  
 
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   David Katz 
 September 16, 2026.
 
 
  SendCutSend made some prototype parts for me.  The did a great job and they did it quickly.  I highly recommend SendCutSend
  
 
  
  
   Google rating score: 5.0 of 5, based on 3480 reviews