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Sheet Metal Welding Services

1 Materials

.063"-.125"

+1-2 days

Production Time

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benefits
Materials
guidelines
what to expect

Welding sizing and options

Part Sizes
A.
.375" x 1.5"
Min part size
B.
30" x 44"
Max part size
1 MATERIALS, .060" - .187"
5052 H32 Aluminum
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.
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Simplified design & ordering

We automatically handle weld compensation and joint normalization.

Optimal integrity and quality

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.
SendCutSend offers sheet metal welding on bend seams on aluminum, mild steel, and stainless steel

“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 5052 aluminum alloys in seven 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

5 thicknesses: .063" – .125"

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

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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 gapNone (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
  • All objects are on the same layer
  • All stray points, duplicate lines, empty objects and text areas have been removed
  • No shapes have open contours
  • All shapes have been united, combined or merged
  • All text has been converted to outlines or paths
  • Cut-out text (reversed text) has bridges or has been stencilized

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Start your first SendCutSend project today!

Upload your CAD design, or try one of our customizable part templates to get instant pricing on your custom laser cut parts. All delivered to your door in a matter of days.

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We accept .ai, .dxf, .dwg, .eps, .stp, and .step

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