Box Builds: Choosing the Most Efficient Metal Fabrication Method
At Baillie Fabricating & Welding, box builds are a common sheet metal fabrication project we handle for customers. These versatile enclosures are used across a wide range of industries and applications and can be customized to meet specific functional requirements. We often create boxes for pharmaceutical and food packaging partners, where stackability and clean finishes are critical.
After so many projects, we’ve gained deep insight into best practices in box builds, and we always like to offer guidance to our customers on the optimal design and manufacturing approaches. Continue reading this blog to learn tips on designing boxes for cost efficiency and find out more about our shop’s experience and expertise.
Formed or Welded? Why We Recommended Forming
In simplest terms, a box build (or a “box bend”) is a sheet metal enclosure with a bottom floor and three or four sides. That concept may sound straightforward, but any number of design choices can significantly impact cost and production complexity.
One of the first manufacturing considerations will be whether to form or weld the box. We usually recommend forming for most applications, because it offers lower costs, better dimensional accuracy, and faster production. There are, however, cases where forming may not be practical.
The Limitations of Formed Box Builds
Forming offers many advantages, but there are practical limitations to the box designs that can be formed. Material thickness is a critical factor; in most standard fabrication scenarios, formed boxes cannot be thicker than 3/16” or 1/4”. Beyond that, the tonnage requirements for the material to be bent may exceed a press brake’s capacity.
Side height is another major limitation in forming boxes. The height of a box’s sides generally cannot exceed the smaller dimension of its base. In practice, it’s challenging to exceed 4” in side height on formed boxes without special tooling, although in some cases we can achieve 6-8”. These taller sizes are most economical in production quantities, though it’s always best to discuss these factors with us.
Combining Welding and Forming
If a design exceeds the limits of forming, we can often combine the two processes for the best results.
For example, we might form two sides of a box, and then weld the remaining sides. This approach allows for significantly taller side heights while still minimizing the total amount of welding required.
When Welding Is the Best Option
Some projects require an all-welded approach from the start. We recommend our welding services when we see:
Thicker materials: For plate thicker than ¼”, even forklifts or cranes may not be capable of handling material in a press brake for complex box bending scenarios. In these cases, welding is more practical.
Non-standard, obscure, or complex angles: Non-standard geometries must often be welded, and curved or radiused sides will also require welding.
Excessive length: Most press brakes are built in 8', 10', 12', or 14' lengths. If a box needs to be 16' long, we typically fabricate it in sections and weld them together.
Putting Your Options to Use
How can you best leverage this information? As we noted, forming is often your most economical option, so we always recommend making design choices that enable forming when possible. If your part’s dimensions or thickness slightly exceed forming capabilities, we suggest trying to alter them if feasible for your part’s application.
Of course, you won’t be alone in trying to make this determination. At Baillie Fab, we’re committed to helping you find the most cost-effective and efficient manufacturing path, whether it’s forming, welding, or a combination of both. We can help you refine your design to reduce costs and improve manufacturability. In our fabricating services, our goal is to deliver a solution that both meets your specifications and supports your success.
Request a quote today to collaborate with our welding and fabrication shop!
