Metal fabrication is a complex and intricate process that involves cutting, bending, and welding metal to create various products. The sector has transformed tremendously in the last few years. The Covid-19 pandemic has acceralated these changes. To ensure success and efficiency in metal fabrication, it is essential to follow best practices that adhere to industry standards and regulations. In this blog, we will explore the top best practices for metal fabrication in 2024.
Metal fabrication industry outlook for 2024
The Indian metal fabrication industry has emerged as a global leader and witnessed rapid development in the past decade. While the global metal fabrication industry is expected to grow at a compounded annual growth rate (CAGR) of 5.5% from 2020 to 2024, the Indian sector should grow faster. The sector showed growth at a CAGR of 6.3% and is expected to reach a valuation of 24 billion dollars by 2024. The growth of this sector is expected to contribute to India’s GDP.
Several factors have fueled this surge. The government’s focus on infrastructure and building has driven demand for metal fabrication. Additionally, several metal fabricators have diversified and are offering pre-engineering services. However, skilled labour shortages and fluctuating prices of raw materials continue to be concerns.
Top 5 Metal Fabrication Trends of 2024
Fabrication is a fascinating subject that is constantly evolving. The top trends you should look out for are:
Automation
The Indian metal fabrication industry is undergoing a metamorphosis, propelled by the rise of automation and, more specifically, collaborative robots (cobots). Driven by the ever-increasing demand for speed and precision, businesses are embracing these advancements to stay ahead of the curve.
Bulky robots are being replaced rapidly. Cobots, smaller and more nimble, seamlessly integrate into existing workflows, collaborating with humans to tackle repetitive tasks like welding, cutting, and material handling. This human-robot partnership not only mitigates the risk of human error and injury but also addresses the labour shortage exacerbated by the pandemic.
This technological revolution isn’t just about replacing humans; it’s about amplifying their capabilities. Cobots, equipped with advanced sensors and AI, are proving to be valuable assets, ensuring consistent quality, optimizing resource utilization, and minimizing costs.
The future of Indian metal fabrication is undoubtedly collaborative. As automation continues to evolve, cobots will become even more intelligent, paving the way for a future of enhanced efficiency, precision, and innovation in the industry.
3D printing
Indian metal manufacturing has embraced 3D printing, or additive manufacturing (AM), in recent years. 3d printing empowers fabricators to manufacture with unparalleled accuracy, especially in the pre-engineering stage. Unlike traditional subtractive methods, AM constructs intricate structures layer-by-layer, saving time and material.
Leading innovators like SpaceX are leveraging 3D printing technology to fabricate intricate, high-performance components like the SuperDraco engine’s combustion chamber. Beyond high-profile instances, AM permeates daily operations, enabling direct printing of casting moulds, metal parts, and prototypes. It is easy to print challenging geometry and shapes.
Metal powder bed fusion is an AM process, that empowers manufacturers to create complex designs with minimal waste, as they can recycle and reuse any unused powder. This technology revolutionizes how metal fabrication occurs and offers new opportunities for innovation.
Internet of Things (IoT) and Industries 4.0
Metal fabrication is embracing the data age with the surge of Internet of Things (IoT) technology. Embedded sensors and devices transform equipment into data-generating powerhouses, offering real-time insights into performance and usage. This treasure trove of information fuels:
- Optimized operations: Analysis empowers precision adjustments, maximising efficiency and cost savings.
- Remote monitoring and control: Teams across locations seamlessly collaborate and manage equipment remotely, enhancing flexibility.
- Predictive maintenance: Data-driven insights anticipate maintenance needs, reducing downtime and extending machine lifespan.
IoT is weaving a digital thread through metal fabrication, ensuring a future of informed decisions, seamless collaboration, and maximized efficiency. Kirloskar Industries employs IoT platforms to remotely monitor CNC machines, reducing downtime by 30% and enabling proactive maintenance. Similarly, Tata Motors leverages sensor data from robotic painting booths to predict maintenance needs, achieving a 40% reduction in downtime and an extended equipment lifespan. Meanwhile, Larsen & Toubro enhances efficiency by integrating IoT sensors into welding robots, leading to a 20% cut in energy costs and a 15% enhancement in weld quality.
Advanced material
tal fabrication is no longer limited to traditional metals like steel. There will be a demand for high-performance alloys, designed for specific properties like strength, corrosion resistance, and durability. In 2024, we should see increased use of advanced materials such as aluminium alloys, titanium alloys, carbon fibre composites, and high-performance ceramics.
These materials offer benefits beyond strength, such as reduced weight, increased performance, and design flexibility.
India is actively embracing these advances with the Advanced Materials and Processes Research Institute (AMPRI), and Bhopal is leading the research and innovation in this sector. Companies like Bharat Forge and Tata Advanced Materials are leading the charge in the private sector by incorporating high-performance alloys into their products.
Sustainability
Every industry is moving towards sustainability due to growing environmental concerns, and the metal fabrication industry is no exception. Today fabrication firms are embracing a greener approach and are adopting energy-efficient processes, minimising waste, and reducing their carbon footprint. That’s not all, they are adopting eco-friendly materials and responsible sourcing, ensuring every step of the way.
Conclusion
The metal fabrication industry is on the cusp of a transformative era. By embracing these trends, businesses can unlock new levels of efficiency, innovation, and sustainability. The future of metal fabrication is bright, and those who adapt and evolve will be at the forefront of shaping this exciting landscape.
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