Design Choices That Help Cut Sheet Metal Costs

As we’ve expanded our sheet metal capabilities at Accurate CNC, we’ve been fielding more questions from customers about what drives the costs behind their quotes. In many cases, the issue isn’t the complexity of the part itself. Instead, a few small sheet metal design decisions make a part harder to produce, and that in turn increases the price.

Factors like material selection, part dimensions, and finishing steps can all have a bigger impact than you might expect. And in many cases, a simple tweak can help bring costs down without changing the function of the part.

If you’ve received a quote from our CNC machine shop that came in higher than expected, here are a few things worth reviewing before you send that final file.

How Part Size Affects Material Cost

One of the biggest drivers of cost in sheet metal projects is how your part fits on a standard sheet. In many cases, the layout looks good in CAD, but once it’s time to cut, things don’t line up the way you’d expect. We’ve had customers design parts thinking two could fit side-by-side on a 48-inch-wide sheet, only to find that the math technically works, but there’s not enough room to actually make the cuts.

In sheet metal design, even a small oversight like this can create material waste. If your part can’t nest with others, or if there's unusable space left over, we often have to charge for the full sheet. 

It helps to understand what your CNC machine shop typically stocks and how they approach nesting. Different cutting processes also have different kerf widths, which affect how close parts can be placed. Even a small size adjustment (sometimes just a quarter inch) can improve material usage significantly.

If you're unsure about how your part will lay out, talk to us. A quick conversation during the early stages of your sheet metal design can go a long way toward keeping your project moving along efficiently.

Material and Finish Choices Can Add Up Quickly

Another source of pricing surprises is material selection. Customers may default to a higher-grade metal by default, like 7075 aluminum or titanium alloys, not realizing how much that drives up cost. 

In many cases, a more common or lower-cost grade like 6061 aluminum may be just as effective for your application. That can cut your material cost significantly, especially if your shop already stocks it. It all comes down to matching the material to the actual application.

Finishing steps can also add unexpected costs. Powder coating and anodizing are great for looks and durability, but they also come with lead times, batch minimums, and setup costs. If you’re only making a few parts, the per-piece cost for finishing can be high. In some cases, it ends up costing more than simply switching to a material like stainless steel, which doesn’t require any coating at all.

We’re seeing more customers take that approach and using thinner stainless in place of powder-coated steel, especially for parts under a quarter inch thick. When it makes sense for the application, that change can simplify production and reduce overall cost by 15 to 20 percent. It also reduces coordination and lead time, as fewer vendors are involved.

Efficient Manufacturing Will Reduce Your Costs

It’s easy to overlook the effect production time has on the total cost of a part. When your sheet metal design includes multiple finishing steps like powder coating, anodizing, or custom colors, your part might end up moving through several different departments or even different vendors. Each of those handoffs takes time, and time almost always adds cost.

We’ve seen this come up when parts are finished in non-stock colors or require special-order powder. Even if the quantity is small, you may end up paying for an entire batch of material just to complete the job. The same goes for coating methods with long lead times or high minimums. And if your base material isn’t something we keep on hand, that delay starts before the first cut is even made.

By choosing commonly stocked materials and finishes, or combining orders when possible, you may be able to reduce both lead time and overall cost. 

Let’s Talk About the Best Way to Build Your Parts

Good sheet metal design isn’t just about how a part looks or functions. It’s also about how efficiently it can be made. From material selection and sizing to finish choices and process steps, small changes can make a big difference in both cost and turnaround.

If you're working on a new project and want to keep things moving without driving up cost, our team is here to help. We’ll review your design, walk through your options, and help you make the most of your materials, processes, and budget.

Ready to get started? Request a quote or send over a rough drawing and we’ll take it from there.