How We Work – Sheet Metal Manufacturing Process

Our design services support the full development of sheet metal products, from early concept through to production-ready manufacturing.

Unifabs works with customers to develop practical designs supported by design for manufacture principles, taking into account material selection, forming methods, assembly requirements and cost efficiency from the outset. This helps reduce unnecessary complexity and ensures parts are suitable for scalable production.

We provide industrial design solutions that support concept development, existing design review and optimisation for manufacture, helping improve performance, reduce cost and ensure consistency in production.

Our dedicated development area and in-house prototyping capability allow components to be quickly produced, tested and refined before full-scale manufacture. With 3D printing available in-house, we can validate component fit and function without delaying tooling decisions.

Whether developing a new product or refining an existing design, our engineering team focuses on making sure parts are practical to manufacture, efficient to produce and aligned with final production requirements.

Our 24 hour fabrication centre with ‘lights out‘ manufacturing capabilities enables high-efficiency production of complex sheet metal components at scale.

The facility includes CNC laser cutting services delivering high-precision profiling, alongside CNC punching services for efficient and repeatable part production. CNC metal bending services using press brakes accommodating up to 4 metre lengths support accurate forming across a wide range of material thicknesses, while automated panel bending services enable complex geometries with consistent repeatability.

We operate across multiple high-capacity production units at Haunchwood Park Drive Nuneaton. With dedicated areas for sheet metal fabrication services, specialist welding bays, laser welding capability, and advanced robotic welding services, we support both medium and high-volume manufacturing requirements.

This combination of automated technology and engineering expertise enables us to deliver high-volume sheet metal fabrication with consistent precision, repeatability and production reliability.

Our finishing operations run continuously, transforming sheet metal into components, sub-assemblies, and fully finished products ready for integration or end-use.

We provide powder coating services using an advanced automated powder coating line supported by manual finishing capability, ensuring consistent surface finish and durability across production volumes. With a dedicated assembly area and specialist team, we deliver mechanical assembly services for components, sub-assemblies, and complete products tailored to customer requirements.

All parts are manufactured in accordance with ISO 9001:2015 quality management standards. This is supported by structured maintenance programmes, pre-shift machinery checks, a comprehensive non-conformance reporting system, and in-process inspection carried out by on-site quality personnel.

This controlled approach ensures finished products meet specification requirements, with consistent quality maintained across repeat production.

Our delivery service is fully integrated into the manufacturing process, ensuring components, sub-assemblies, and finished products are supplied reliably and on schedule.

Unifabs operates from a 60,840 sq. ft. manufacturing facility in the West Midlands, enabling efficient distribution across Birmingham, Leicester, Coventry, and nationwide. Deliveries are supported by a dedicated fleet and coordinated logistics planning to ensure products arrive in line with production and supply chain requirements.

We support flexible delivery models, including scheduled supply, direct-to-line delivery, and just-in-time (JIT) manufacturing supply. This helps our customers to reduce storage requirements and maintain production flow.

Where required, products can be delivered directly to end customers, supporting OEM supply chains and subcontract manufacturing agreements via our subcontract manufacturing services.

Sustainability is integrated into our logistics approach, with reduced use of single-use plastics and increased use of recyclable packaging. For regular repeating deliveries, we use reusable transport containers to reduce waste, minimise environmental impact and improve handling efficiency.