Processes
Laser vs punch, rapid prototyping to mass production, and turnkey assembly.
Rapid prototyping
How long does sheet metal prototyping take?
Three to seven business days from drawing approval for laser-cut and CNC-bent parts. Because laser cutting and press-brake bending need no tooling, a prototype can be produced without any up-front die investment. Start a sample at the prototyping page.
Is there a minimum order quantity for prototypes?
One piece. Sheet metal fabrication carries no tooling cost, so a single prototype and a fifty-piece pilot run use the same process and the same drawing.
What files do you need to quote a prototype?
STEP, IGES or a 3D PDF for the geometry, and DXF or DWG for flat parts. A drawing carrying tolerances, material and surface finish removes ambiguity; if there is no drawing yet we quote from the 3D model and flag what needs specifying.
Can the design still change after the first sample?
Yes — that is the point of prototyping on laser and brake. Revisions are re-cut rather than re-tooled, so a changed hole pattern or bend radius costs setup time, not a die. We track the drawing revision against each sample.
What happens once the prototype is approved?
The approved drawing moves to whichever process suits the volume — turret punching or progressive die stamping — while keeping the same datum scheme and inspection plan, so the production part matches the sample you signed off.
How much does a sheet metal prototype cost?
Prototyping carries no tooling cost, so price is material plus a little setup and programming - generally far below a tooled part. Use the cost calculator for an indicative number, then a senior engineer confirms within 24 hours.
Can I prototype in the same material as production?
Yes. Prototypes are cut and bent from the production-grade alloy (5052, 304, etc.), so the sample's fit and finish match the eventual run. See the materials library for the grades we keep in stock.
What is the fastest way to get a prototype made?
Send a STEP or IGES model through the quote form; laser cutting and press-brake bending need no tooling, so a sample is often cut the same day the drawing is approved. Sampling runs 3-7 business days.
Can the prototype move straight to mass production?
Yes. The approved drawing transfers to turret punching or progressive-die stamping without changing datum or inspection plan, so the production part matches the sample you signed off. See mass production for the volume step.
What bend radius and hole rules apply to my prototype?
The same DFM rules as production: keep bends at or above the minimum radius for the alloy (1×t for 5052, 2–4×t for 6061) and holes at least 2× thickness from bends and edges. Because prototypes are laser-cut and bent with no tooling, a design change is a re-cut rather than a re-tool, so you can tighten or relax these during sampling. Our DFM guide and bend radius guide explain the limits.
Low volume
What is the minimum order quantity for low-volume sheet metal?
From 50 pieces, with no tooling charge. Laser cutting and CNC bending handle low volume economically because setup is the only fixed cost — there is no die to amortise. See low-volume production for typical lead times.
Is low volume more expensive per part?
Per-unit cost is higher than at volume because setup, programming and inspection spread over fewer parts. The gap narrows sharply after a few hundred pieces, which is the point at which tooling starts to pay for itself.
When should a part move from low volume to tooling?
When annual demand passes a few thousand pieces and the geometry has stopped changing. Before that, laser cutting plus punching keeps the unit cost competitive without freezing the design into a die.
Can the same part run at low volume and later at high volume?
Yes. The drawing, datum scheme and inspection standard stay unchanged, so the part simply changes process — the same factory, the same quality system and the same engineering contact throughout.
What lead time applies to a low-volume release?
Seven to fifteen business days for standard production once the drawing and finish are fixed, with sampling in three to seven days where a first article is required before the full release.
What counts as low-volume sheet metal production?
Runs from 50 pieces up, where laser cutting and CNC bending keep unit cost competitive without a die. As demand passes a few thousand, tooling starts to pay - see mass production for that step.
How should I cost a low-volume batch?
Setup, programming and inspection spread over the batch, so per-unit cost falls as quantity rises to a few hundred. The cost calculator gives an indicative price; a senior engineer confirms the firm quote within 24 hours.
Can low-volume parts use the same finish as production?
Yes. Powder coating, anodizing, plating and laser engraving are all available on low-volume runs, carried out by our licensed partner plants to specification and inspected by us. See the finishes overview.
Is low volume right if my design might still change?
Yes - keep laser cutting plus punching until the geometry freezes, because revisions re-cut rather than re-tool. Move to a die only once annual demand and the design are stable. Discuss the path in the quote.
Mass production
What volume justifies progressive die stamping?
Roughly a few thousand pieces upward, once the geometry is stable. Below that the die investment rarely pays back; above it, the per-part cost falls well below laser-cut and bent alternatives. See mass production for tolerances and tooling.
Do you design and build the stamping dies yourself?
Yes. Die design, manufacturing, trial run and maintenance all happen in our own die workshop, so a tooling change does not wait on a third party and the die stays matched to the production presses.
What tolerance do you hold on stamped parts?
Progressive-die stamping holds ±0.01 mm on formed features, with piercing and blanking held to the drawing datum. Where a feature is not critical, saying so on the drawing keeps the die simpler and the part cheaper.
How is quality controlled at production volume?
First-article inspection per drawing revision, in-process sampling at each station, dimensional reports on the critical-to-function features, and batch traceability from the raw coil to the packed part.
Can you run a die that we already own?
Yes, after a trial and a tool-condition assessment. We report what the die can hold before committing to a production schedule, so a worn tool does not turn into a quality surprise halfway through the order.
How long does tooling take before mass production?
Die design, build and trial run typically take a few weeks depending on stations and complexity, all in our in-house die workshop. Because we own the tooling, changes are fast and the die stays matched to our presses.
What is the cost advantage of progressive-die stamping?
Above a few thousand pieces, per-part cost falls well below laser-cut and bent alternatives because setup spreads over the run and cycle times drop to seconds. Below that, laser plus punching is cheaper - see low volume for the crossover.
What is the lead time for mass production stamping orders?
Once the die is qualified, recurring stamping runs are scheduled against your order cadence, with first-article sign-off before each new production release. Lead time is quoted per order from die and press capacity and confirmed when you place the call-off. Discuss volumes and cadence in the quote so we can commit to a firm schedule.
Can WERIX run a stamping die we already own?
Yes, after a trial and tool-condition assessment; we report what the die can hold before committing to a schedule so a worn tool does not become a mid-order surprise. Discuss transfer tooling in the quote.
What tolerance can stamped parts hold versus laser-cut parts?
Progressive-die stamping holds ±0.01 mm on formed and pierced features because the die fixes the geometry; laser-cut and bent parts hold ±0.1 mm on cuts and ±0.5° on bends, set by programming and the press. For high-volume, tight-tolerance features, stamping wins; for low-volume or frequently changed geometry, laser plus bend stays cheaper. See mass production for the volume crossover.
Assembly & integration
What does turnkey assembly include?
Component manufacturing, incoming inspection, sub-assembly, final assembly, functional testing, inspection, labelling, custom packaging and shipment — all under one purchase order and one accountable team. Explore the full assembly scope.
Can WERIX manufacture the metal components before assembling them?
Yes. Enclosures, brackets and chassis are laser-cut, CNC-bent and welded in the same facility, so components reach the assembly line already inspected against your drawing.
Can you install PEM fasteners and other hardware?
PEM studs and nuts, rivet nuts, standoffs and captive screws are pressed to specification, with push-out and torque checks recorded on the first article and sampled through the run.
Can you perform mechanical and electrical assembly?
Mechanical assembly is standard, and wiring harness routing, connector fitting and cable management run on dedicated sub-assembly lines. Product safety certification for the finished unit stays with your nominated laboratory.
Can you perform functional testing?
Test routines are written with you per project — continuity, insulation resistance, fit checks or IP65 ingress checks — and results are recorded per unit or per batch before release.
Can you provide custom packaging?
Yes. Foam inserts, labelled cartons, kitting and palletisation are built to your specification, including retail-ready and drop-ship packaging.
Can you ship finished products directly to our facility or our customers?
Yes. Finished, tested units can ship direct to your factory, warehouse or end customer, using your documentation, labelling and carrier.
Can WERIX manage the complete manufacturing and assembly process?
Yes — from raw material and sheet metal fabrication through assembly, testing and packaging, one factory and one purchase order cover the whole path to a finished product.
What is turnkey sheet metal assembly?
One purchase order covers component manufacturing, inspection, sub- and final assembly, functional testing, labelling, custom packaging and shipment - a single accountable team from raw sheet to finished product. See the assembly service overview.
Can WERIX insert PEM fasteners and press hardware?
Yes. PEM studs and nuts, rivet nuts, standoffs and captive screws are pressed to specification, with push-out and torque checks recorded on the first article and sampled through the run. Tell us the hardware schedule and it is quoted with the part.
Does WERIX do electrical and wiring assembly?
Mechanical assembly is standard, and wiring harness routing, connector fitting and cable management run on dedicated sub-assembly lines. Product safety certification for the finished unit stays with your nominated laboratory. Our in-house capabilities keep components and assembly under one roof.
Can finished assemblies ship directly to my customers?
Yes. Tested units can ship direct to your factory, warehouse or end customer using your documentation, labelling and carrier - drop-ship ready. Discuss fulfilment in the quote so logistics are built into the order.
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