Steve Elliott

Does Your Part Really Need Galvannealed Steel?

When you spend as much time quoting custom metal fabrication projects as our estimating team does, you become well attuned to trends in material cost. One thing we’ve noticed recently is that galvannealed steel costs keep rising.

If your sheet metal design has specified galvannealed steel for years, it can be easy to assume it’s the best material for the job. However, taking a few minutes to think about your design’s real-world needs and whether they can be fulfilled by another material option can help you cut costs without sacrificing quality.

In some cases, galvannealed steel is still the best material for your application. But it’s also very possible that another, less expensive material will work just as well.

When Galvannealed Steel Is Worth Keeping

Despite its higher cost, galvannealed steel has advantages. Its zinc-iron coating provides corrosion protection and a surface that works well for painting or powder coating. It can also be useful for certain welding applications, particularly spot welding. Here are a few questions to ask about your sheet metal design to determine whether this material, or a comparable alternative, makes sense for your part:

Will the part be painted or powder coated, and is coating adhesion important?
Do appearance and finish consistency matter?
How will the part be welded, and does the material affect that process?
Are both corrosion protection and painted finish performance essential?

A “yes” to any one of these questions doesn’t automatically mean galvannealed steel is required. But when several of these requirements come together, or a customer specification calls for it, galvannealed may be the right choice. Common applications include automotive body panels, electrical enclosures, commercial doors, and painted industrial products.

Alternatives to Galvannealed Steel

The right material for your custom metal fabrication comes down to the application and end-use requirements. Here are a few materials we might recommend as alternatives to galvannealed steel if your sheet metal design allows for a material change.

Cold-Rolled Steel (CRS)

For appropriate indoor applications, cold-rolled steel often offers the greatest potential for material cost savings. It lacks galvannealed steel’s zinc coating (and the added cost that comes with it), so it’s generally best for indoor parts. Paint or powder coating can provide corrosion protection, but the part’s exposure and expected service life still matter.

Galvanized Steel (G60/G90)

Galvanized steel may be a good choice when zinc-based corrosion protection is needed. G60 and G90 refer to different zinc-coating weights, so the right choice depends on how the part will be used and exposed. Galvanized steel is frequently used for equipment housings, enclosures, structural components, and outdoor applications. If the part will be painted, galvanized steel may require more preparation than galvannealed steel to achieve the desired finish.

Hot-Rolled Steel (HRS)

Hot-rolled steel may be another lower-cost alternative for parts without tight dimensional tolerances or high surface-finish requirements.

Aluminum

When low weight, corrosion resistance, or fabrication needs favor aluminum, it’s worth evaluating whether it makes sense for the sheet metal design. However, aluminum isn’t necessarily less expensive, so it needs to be evaluated project by project.

Other Coated Steels

Depending on the application, electrogalvanized steel, Galvalume® and other aluminum-zinc-coated steels, or other zinc-coated sheet metal products from domestic mills may also be worth a look. These materials might be viable when corrosion resistance is important but galvannealed steel’s paintability advantages are not essential.

How to Evaluate a Material Change

If your sheet metal design currently specifies galvannealed steel and you’re interested in exploring alternative material options, it’s important to consider the environment, exposure, finishing needs, expected service life, cosmetic and structural requirements, and how the part must be formed and welded.

It’s also important to consider that the lowest material price doesn’t always produce the lowest overall part cost. A material change may necessitate changes to how the material is cut, bent, welded, and finished. It can also affect tooling, lead times, and material availability.

If your sheet metal design calls for galvannealed steel because the application requires it, then by all means, keep using it. But if it’s being used simply because that’s how it’s always been spec’d out, and no one has considered alternatives, it may be worth exploring your options.

At Nu-Way Industries, we’re happy to work with your engineering and purchasing teams to evaluate material alternatives based on your part’s actual requirements. Request a quote to get started.

Weld, Fasten, Clinch, or Bond? How Joining Choices Affect Sheet Metal Fabrication

In sheet metal fabrication, joining methods are often treated as a production detail: add a weld here, place a rivet there, specify a clinched joint or structural bonding adhesive. But the joining method you choose can affect much more than how two parts are held together. It can also influence cost, cycle time, sheet metal finishing requirements, lead time, and the sequence of operations needed to build the part.

At Nu-Way Industries, we often receive a part number, a drawing, and a joining callout without the full picture of how the part will be used. We can still quote from the print, and in many cases, the joining method shown is exactly what the application requires. But when we understand the end use, we can have a more useful conversation about whether there may be a faster, cleaner, lower-cost, or more production-friendly joining option.

Of course, nobody knows your product better than your team. But the earlier we’re part of the discussion, the more we can do to help make sure the joining method supports how the part actually needs to perform while still respecting the design intent behind it.

Common Ways to Join Sheet Metal Components

Most sheet metal joining decisions come down to a handful of methods, each with its own cost, strength, finishing, and production implications. Looking at those trade-offs early can help confirm whether the joining method on the print is the right fit as designed, or whether an approved alternative is worth talking through.

Mechanical Fastening

Mechanical fastening is often the most economical starting point for joining sheet metal components. This category includes rivets, bolts, and other loose fasteners, along with pressed-in hardware such as PEM-style inserts and interference-fit joints. The appeal of mechanical fastening is speed and cost. Installing a rivet or fastener typically requires no heat, minimal setup, and less labor cost than many welded joints. The trade-offs are that many mechanical methods require holes, overlaps, or additional hardware, and they may not be the right fit for high-vibration or strength-critical applications where a fastened joint could eventually loosen.

Welding

Welding includes processes such as MIG, TIG, spot, and laser welding. These methods fuse the metal itself, creating a strong, permanent joint that mechanical fastening may not be able to match in certain applications. For structural loads, sealed assemblies, or parts exposed to heavy vibration, welding is often the right call, and in some cases, it may be the only acceptable option.

The trade-offs vary by process and production volume. MIG and TIG welding can be labor-intensive, and if the finished part needs a clean cosmetic surface, the weld may need to be ground flush and blended. Spot welding can sometimes reduce the amount of visible finishing required. When the volume and geometry support it, MIG, TIG, or laser welding can be automated. Automation requires additional setup but can improve consistency and cycle times across the production run.

Clinching

Clinching is a mechanical joining method that uses a punch and die to press two or more overlapping layers of sheet metal into a permanent interlocking joint, without welding, rivets, or added hardware. In automated applications, the connection can be formed in less than a second. TOX® is a trademarked name for this type of clinched connection.

Because clinching is a cold-forming process, it avoids heat-related distortion and the need for filler material or separate fasteners. It can be a fast, repeatable option for joining materials with different thicknesses or compositions, including pre-coated stock, while potentially reducing the need for post-join finishing. Suitability depends on the materials, combined thickness, joint geometry, required strength, and access for the punch and die. For applications involving extremely high strength requirements, thicker materials, or critical structural joints, welding may still be the better choice. But when conditions allow, clinching can be an efficient, lower-cost alternative.

Structural Bonding Adhesives (SBA)

Structural bonding adhesives and high-bond tapes join parts across a surface rather than at discrete points. This approach can distribute load across a bonded area and avoids the heat-related distortion and drilled holes that other methods can introduce, which is one reason it shows up frequently in automotive assembly. Like clinching, it can be a practical option in applications where welding is not always possible or economical. As with any joining method, SBA fits some applications better than others, and the right approach depends on what the part has to do.

The End Use Determines What Is Possible

End use matters because a joining method is often selected for a specific purpose that may not be apparent from the drawing alone. Without knowing how a part will be used, where it will operate, or what it needs to withstand, it can be difficult to tell whether the method on the print is fixed or whether there is room to discuss an approved alternative.

Sometimes the end use makes the method non-negotiable. If a component has to contain pressure, support a critical load, or meet a specific safety standard, the application may dictate the joint, and the right move is simply to build it as specified.

Other times, understanding the end use can point toward a different approach. A part destined for a high-vibration environment, for example, may not be a good candidate for certain fastened joints if there is a risk that the connection could gradually work loose. Knowing that the part will face heavy vibration gives us a chance to flag that concern early and talk through a more durable approach before it becomes a field problem.

The takeaway is that the more we understand about what a part does and where it will be used, the more useful the conversation becomes. That context is what separates quoting a print from helping identify the best manufacturing path for the application.

Sometimes the Best Joint Is No Joint

Before choosing between the various joining methods, it’s worth stepping back, because the best joint is often the one you can eliminate entirely. In the right cases, a feature that was going to require a weld or fastener may be able to be formed directly into a single part instead.

In addition to removing the joint itself, consolidating parts this way can reduce labor, hardware, the finishing work around the joint, and the tolerance stack-up that comes from assembling multiple pieces. Fewer parts can mean lower cost, faster production, and one less thing that can shift out of alignment during assembly.

Consolidation is not always possible. Geometry, material, bend access, strength requirements, and the original design intent all play a role, and sometimes joining separate parts really is the right answer. But it’s one of the most valuable questions to ask early, while the design is still flexible, because once the part is finalized, that opportunity is usually gone.

Joining Choices Affect Finishing, Cost, and Lead Time

In addition to determining how parts come together, the joining method can change the sequence of operations required to manufacture an assembly. Those downstream effects can influence labor, part movement, finishing requirements, and overall production time. A few examples:

– Manufacturing and finishing sequence: A welded design may move from fabrication to welding, then through grinding or blending before the completed assembly is powder coated. A mechanically fastened design may allow the individual components to be fabricated and powder coated first, then brought together for final assembly. Clinching can sometimes be used with pre-coated materials without the heat damage associated with welding, while SBA may require specific surface preparation before the adhesive is applied.
– Appearance requirements: A MIG weld may be fine on a hidden structural surface, but a visible surface may need that weld ground flush and blended, which adds labor. Spot welds are often less visible and may require little cosmetic finishing. Clinched joints leave a formed impression, while SBA can create a clean exterior without visible welds or fasteners.
– Lead time: If timing is a priority and the application allows for an approved alternative, choosing a faster joining method may help the part move through production more quickly. Clinching can provide a fast, repeatable process with little post-join finishing, while SBA can reduce finishing but introduce curing time, so the full production sequence needs to be considered.

The cost of a joining method should therefore be evaluated not just as a single operation, but by the manufacturing steps it adds, changes, or eliminates throughout the process.

In each of these cases, the goal is to talk through the options early, while the design is still flexible. Any change to the print would always go through your team for review and approval first.

Choosing the Joining Method That Fits the Part

The best joining method depends on more than strength, speed, or cost. It depends on what the part actually has to do.

That is why end-use context matters. If Nu-Way understands how the part will be used, where it will operate, what it needs to withstand, how it should look, and how quickly it needs to move through production, we can have a more useful manufacturing conversation. Sometimes the print is already showing the right approach. Other times, there may be an approved alternative that reduces cost, simplifies finishing, improves lead time, or eliminates a joint entirely.

It’s important to reiterate that any alternative we suggest is offered for review, never implemented on our own. The final decision belongs to your team, and if there is a reason a part has to be joined a certain way, we respect it. Our role is to bring manufacturing experience to the discussion early, while there is still room to weigh the options.

If you are developing a sheet metal assembly and want to choose the right joining approach for cost, strength, finish, and production, request a quote today. Nu-Way Industries can help you think through the manufacturing path before the design is finalized.

How Early Collaboration Helps Control Sheet Metal Costs

Anyone who works in purchasing knows that a sheet metal quote can raise questions that aren’t always obvious from the print alone. A part may look straightforward, the drawings may be complete, and the material callouts may all appear reasonable. But when you understand the entire scope of the project (ie. how all these individual parts are being used together) from a manufacturing standpoint, small details in the design can have a meaningful impact on price, lead time, and production efficiency.

At Nu-Way Industries, we recently reviewed an enclosure assembly that demonstrates how much those details matter. The enclosure was roughly desktop-sized and made from about six sheet metal components. At first glance, it looked like a routine sheet metal assembly. But once our team reviewed how the components would be cut and nested, the cost drivers became clearer. Every part called for a different material thickness, and one unfolded component consumed nearly an entire sheet of material on its own. If more of the parts had shared a common gauge, some of the smaller ones may have nested into that unused sheet area instead of leaving it as scrap.

To be clear, that doesn’t mean the design was wrong. Each material choice may have made sense on its own, especially from a performance standpoint. But from the fabrication side, those choices limited nesting opportunities and created material waste that the individual component prints didn’t fully show.

That’s why it helps to bring your manufacturing partner into the conversation early. When Nu-Way understands what the part needs to do and engineering has room to weigh in, there may be practical ways to improve cost, yield, or lead time before the project moves into production.

Where a Manufacturing Partner Can Help You Spot Hidden Cost Drivers

When Nu-Way reviews a project for quoting, our team looks at how the part will move through production, including material usage, nesting, outside processing, sourcing, and scheduling. That manufacturing perspective can reveal cost drivers that may not have been obvious during design or purchasing.

Material Yield Adds Up Across an Assembly

In many cases, the material cost isn’t limited to the metal inside the finished part’s perimeter. The sheet metal quote also has to account for the material consumed to make the part, including the skeleton, cutouts, and leftover areas that may not be usable once the part is cut.

That unused material is where the assembly-level view can make a difference. If six related parts all use different gauges, the shop is essentially working with six separate material requirements. But when several of those parts can share a common material thickness, there may be room to nest them together more efficiently and reduce the amount of unused material.

Not every material callout can or should be changed. Some thicknesses are selected for strength, fit, or performance. But when the reason is less clear, it’s worth asking the question before the quote is finalized or the PO is placed. If the design intent allows for a common gauge, a different sheet size, or a small adjustment to how parts are grouped, the result may be a lower-cost, more efficient production path.

Outside Processing Can Carry Minimum Charges

Some sheet metal quote surprises come from what happens after the parts are fabricated. If a part needs wet paint, plating, anodizing, or passivation, Nu-Way typically sends that work to a specialized outside vendor, which is common for many job shops. That outside processing has to be included in the quote, and on small orders, the pricing can look disproportionate to its size or complexity.

Those vendors often charge a minimum lot fee to set up and run a batch. On a small order, that minimum gets absorbed by just a few parts. Ten small plated brackets, for example, may come back much higher than expected on a per-piece basis because those ten pieces are carrying the entire finishing minimum on their own.

This is one place where grouping related parts can help. When several parts need the same finish, they may be able to move through production and outside processing as a family, spreading the minimum charge across a larger run instead of applying it to one small batch. Capturing that benefit usually takes a small adjustment on the purchasing side. The related parts need to be ordered and processed as a set, rather than as separate one-off POs, so the fabrication partner can manage the finishing as a single lot.

Material Availability Can Change the Best Approach

Raw material pricing and availability have been changing quickly, which makes early conversations more important during quoting and planning. Steel, aluminum, copper, and stainless have all seen price movement, and some materials that used to be easy to source are now harder to get on a predictable timeline. When a service center is out of a given material, filling the order may mean waiting on the mill, which can push lead times beyond what the buyer expected when the RFQ package went out.

That uncertainty is worth surfacing early, because there are often options once everyone understands the tradeoffs. If the specified material is expensive or hard to source, the next question is whether the part really needs that exact material to do its job. Could a different grade work? Is there a more available thickness? If the print calls for aluminum, would powder-coated steel still hold up in the application? While those are engineering decisions, Nu-Way can help raise the question before cost or lead time becomes the only thing left to react to.

Once the material choice is clear, the next step is to discuss timing. When material is scarce or a project requires a larger commitment buy, the customer and manufacturer may need to talk through how that material will be secured. In some cases, locking in price and availability calls for a firmer purchasing commitment up front, so the material can be purchased, scheduled, and held for the work ahead. Getting those conversations on the table early gives everyone room to weigh cost, availability, and timing before the order is locked in.

Better Sheet Metal Quotes Start With Better Conversations

None of this is about second-guessing the design or adding steps to an already busy process. A print can be complete and correct and still leave room to improve how the part is produced. Purchasing, engineering, and your fabrication partner each see the project from a different angle, and the earlier those perspectives come together, the more options everyone has to manage cost, yield, and lead time.

That’s the real value of treating a manufacturing partner as an extension of your own team rather than another name on a bid list. The work still gets built to print. It just gets built with fewer surprises.

Ready to talk through your next project? Get in touch with the Nu-Way team to request a quote.

Why Your RFQ Should Include More Than Just a Drawing

Buyers, here’s a question: Could you use some time back in your day? Between sending out RFQs, waiting for responses, and juggling timelines, the answer is probably yes. If you aren’t already doing so, one of the simplest ways to speed up the quoting process is to include the 3D CAD file with the drawing.

The Role of 3D CAD Files in Modern Quoting

If you’re already providing your manufacturing partners with a drawing, why does the 3D CAD file matter so much? It comes down to speed, as the 3D file fundamentally changes how fast a supplier can turn your RFQ around.

For decades, estimators manually interpreted every dimension, every spec, and every note from a drawing before they could even start quoting. They relied on spreadsheets and custom calculators to work through the numbers, making it a methodical and very manual process. Modern quoting software has changed that. Today, the software can analyze part geometry directly from the 3D file and automatically determine:

– Part features (such as holes, countersinks, and counterbores)
– Sheet metal flat patterns and blank sizes
– Part volumes
– Types of manufacturing operations

With the software handling the setup, estimators can jump straight into evaluating cost and manufacturability instead of spending time on manual calculations. Think of the 3D file as a force multiplier. For example, rather than manually calculating the total number of inches in a perimeter that resembles Rhode Island’s coastline, the software figures it out instantly. The drawing and 3D model work in unison: while the 3D file builds up the geometry, the drawing communicates specs, tolerances, and design intent. It’s the one-two punch that gets the quote done faster.

What a Missing 3D CAD File Actually Costs You

Without the 3D model, estimators have to manually interpret the drawing and approximate the information that software could otherwise extract automatically. It still gets done, but it takes longer, which means your quote takes longer to come back.

The bigger issue, however, is what happens downstream. If a supplier wins the order and the buyer didn’t provide a 3D file, their engineering team often has to recreate the 3D model from the drawing before production can even begin. That’s time on the supplier’s side, which you feel in the form of longer lead times.

Recreating the model is also where real risk enters the picture. Think about a part with 200 dimensions. When a manufacturing partner has to recreate that model from only your drawing, every single measurement is entered manually. Across 200 entries, it’s almost inevitable that someone will miskey a number. And if that mistake doesn’t get caught before production, you could end up with a thousand parts that don’t meet spec. What started as a missing file turns into rejected parts, quality teams getting involved on both sides, discrepant material reports (DMRs), credits, rework, and a whole lot of back-and-forth that really didn’t need to happen.

There’s also a less obvious benefit to including the 3D file: it acts as a built-in cross-check. There have been plenty of cases where a customer’s 3D model didn’t match their own drawing. When both are included, that discrepancy is caught early rather than showing up on the production floor. The two files should be in sync with each other, not conflicting, and having both in hand is what makes that verification possible.

What to Include in Your RFQ Package

A strong RFQ package includes a STEP file (the universal 3D CAD format) and the drawing. That’s the baseline, and for most parts, it’s all a supplier needs to get moving quickly.

For assemblies or weldments, the best approach is to export the top-level assembly as a STEP file, include the corresponding drawings, and package everything into a ZIP file or a shared folder. Most CAD software can export assembly STEPs that include all child-component geometry, so suppliers can analyze the full assembly without requesting each piece individually. Nu-Way can also accept (and it’s preferred) if the customer sends native Solidworks files using the “Pack n’ Go” feature which makes it simple to gather up those files.

The good news is that your facility almost certainly already has these files since manual drafting of these drawings seldom happens today. Instead, the part gets drawn in 3D, and the software converts it to a drawing. It’s always going from that workflow, never the other way around.

In other words, the 3D CAD file exists. It’s just a matter of including it. In most cases, all you may have to do is ask engineering.

Make Including 3D Files the New Routine

As technology continues to advance, this process is becoming the new normal across the manufacturing industry. In fact, many OEMs have been including 3D files in the quoting process for many years now. They know that better RFQ data leads to faster quotes, faster order processing, reduced lead times, fewer errors, and less back-and-forth.

If you want to streamline the RFQ process and help prevent downstream quality headaches in your manufacturing operation, including the 3D model along with the part drawing is one of the simplest ways to do so. It means faster response times from your manufacturing partners and a more efficient timeline from quote to production.Put it into practice. Send us your next RFQ with the drawing and the 3D file, and see the difference it makes. Request a quote from Nu-Way Industries.

Supporting the Data Center Industry Boom With Custom Metal Components

Data centers are driving one of the biggest manufacturing booms our nation has seen in years. As businesses and individuals lean further into AI and cloud computing, global data center capacity is expected to double by 2030, with nearly 100 gigawatts of new capacity coming online.

Most headlines focus on the technology inside these facilities. Less visible is the physical infrastructure that makes it all possible. From cooling systems to backup generators to server infrastructure, all of it relies on enclosures, racks, control cabinets, and other precision sheet metal components.

Nu-Way Industries has been fabricating these types of components for decades. As demand for data center infrastructure accelerates, that experience matters.

Where Nu-Way Fits in the Supply Chain

Nu-Way Industries plays a role in the data center supply chain, even if our name never appears on the finished equipment inside those buildings. Instead, our company supports the tier-one suppliers responsible for delivering the systems that power and protect modern data centers.

Those companies design and integrate everything from server infrastructure to cooling equipment and backup power systems. To manufacture those systems at scale, they rely on fabrication partners capable of producing the custom metal components that support their designs.

As a precision metal fabrication partner, Nu-Way works behind the scenes to help those suppliers deliver reliable systems while keeping demanding project timelines on track. In many cases, these suppliers need fabrication partners who can quote quickly and keep production moving without delay.

What Nu-Way Fabricates for The Data Center Industry

While the components used in data center infrastructure vary widely, they share a common set of requirements: precision, durability, and reliable production at scale.

At Nu-Way, we fabricate a range of custom metal components for tier one suppliers, including:

– Server racks and enclosures
– Control cabinets
– Generator enclosures and housings
– Heavy base weldments for backup generators, designed for forklift placement onto concrete pads

And because everything is handled under one roof, these aren’t partial assemblies waiting on additional components or processing steps from other vendors. With precision sheet metal forming, welding, powder coating, and electromechanical assembly all in-house, our team delivers finished components ready for integration, helping suppliers streamline their own production processes.

Why Nu-Way Is Built for This Moment

The data center boom may be new, but many of the components it relies on are not. Nu-Way has spent decades fabricating enclosures, racks, and control cabinets for industries that laid the groundwork for today’s infrastructure, including telecom, power generation, and server systems.

That history has practical value. After years of working across these industries, Nu-Way’s team has seen countless design configurations. That experience allows us to fabricate to exact specifications or recommend alternatives that achieve the same result at lower cost. When a supplier needs to scale from prototype to hundreds or thousands of units, the capacity is already in place.

If you’re looking for a precision metal fabrication partner who understands the data center industry, Nu-Way is ready to help. Reach out to discuss your next project.

The Hidden Costs of Off-the-Shelf Sheet Metal Enclosures

When it’s time to build enclosures, is your team’s go-to process opening a catalog and ordering an off-the-shelf option?

For prototyping, that makes perfect sense. But when volume kicks in, that same decision could be costing you more than you realize.

Nu-Way Industries is a custom sheet metal enclosure fabrication partner that helps OEMs move from high-priced catalog boxes into value-driven custom enclosures. With precision sheet metal forming, electromechanical assembly, and in-house powder coating under one roof, Nu-Way delivers custom sheet metal enclosures that arrive ready to load, eliminating the modifications, wasted material, and hidden costs that come with catalog enclosures at scale.

Catalog Boxes Have Their Place

When you’re instructed to “hurry up and make a prototype,” that’s what you do. And there’s typically no faster or more cost-effective way of doing so than purchasing a few simple off-the-shelf catalog boxes. At this stage, it can be difficult to justify the cost of custom sheet metal box in small quantities. But once the design is finalized and volume ramps up, those off-the-shelf options suddenly get expensive. Even with a volume discount, those catalog sheet metal enclosures are often far more expensive than a custom-fabricated solution.

It’s not just the cost of the box itself that drives expense, but also the time required to get it ready for use. Before catalog enclosures can be loaded, someone must spend time drilling holes, adding lances, installing studs, and making whatever other adjustments are needed to prepare it for assembly. That labor adds up, but because it’s happening on the production floor rather than in the purchasing process, it’s easy to overlook.

Unless buyers are given this context and visibility into potential savings, they’ll often continue sourcing what they always have. That’s why production teams must communicate what’s actually involved: “We do a lot of work to this catalog box before we can even load it.” When buyers understand the full picture, they can start asking the right questions and exploring sheet metal fabrication services that eliminate that hidden labor.

The True Cost of “Close Enough”

When selecting sheet metal enclosures from a catalog, you’re limited to what’s available. One option is too short, another is too shallow, and you end up with an oversized enclosure simply because it’s the closest available fit. Add to that all the labor involved in modifying each box before it’s ready for assembly, and the true cost of “close enough” comes into focus.

Wasted Material

A larger box means more material, and more material means higher per-unit costs. A custom fabricator looks at what’s actually going inside the enclosure and right-sizes it accordingly. In some cases, that means questioning design choices that were only made because of catalog limitations. Does the enclosure really need a double door, or would a single door with one hinge and one lock do the job for less?

Wasted Space

Oversized enclosures take up more room on the production floor, in storage, and at the final installation site. In industries where space is already at a premium, that footprint matters.

Shipping and Logistics

Larger boxes mean fewer units per pallet, which means more pallets, more shipments, and higher transportation costs. Reducing the enclosure size to fit actual needs creates a domino effect that goes well beyond the unit price.

Backplanes and Internal Components

Many catalog enclosures can be ordered with or without backplanes, but those backplanes typically arrive as blank pieces of sheet metal with no features. OEMs are then left to remove and modify them to accommodate mounting points, wiring, and internal components.

With custom fabrication, those features are built into the sheet metal backplane from the start, ensuring proper fit and alignment.

Door Modifications

Doors on catalog enclosures often require additional customization. Cutouts for windows, switches, indicator lights, or HMI panels are rarely included, forcing teams to modify doors after purchase.

A custom fabricator can incorporate these features directly into the door design, improving consistency and ensuring everything is positioned exactly where it needs to be.

What Custom Fabrication Delivers

When you work with a custom fabricator, the enclosure arrives ready to load. Every hole, lance, stud, and fastener is already in place, eliminating the modification work that eats up time on your production floor.

But the benefits go beyond labor savings. A custom fabricator asks questions that a catalog never will: What’s your end use? Do you really need all this space? Would a single door work instead of a double? These conversations lead to right-sized enclosures that reduce material costs and simplify the final product.

Working with a partner like Nu-Way Industries means accessing multiple capabilities under one roof:

– Precision sheet metal fabrication services
– In-house powder coating, including custom colors to match your brand
– Electromechanical assembly and integration

That means fewer vendor handoffs, faster turnaround, and a finished sheet metal enclosure that’s ready to go the moment it arrives. When you hit that tipping point where modifying off-the-shelf units just isn’t worth it anymore, Nu-Way is ready to help. We’ll look at what’s going in the box, ask the right questions, and build a solution that fits.