Metal brackets. These metal pieces are frequently out of sight, and it is easy to overlook them due to their small size or unappealing design. Despite this, metal brackets serve a wide variety of purposes and are indispensable in many different fields. They are the unsung heroes of many structures around us, whether a building, a large machine, or furniture. Join us as we explore this topic to understand metal brackets better.

So, what is a metal bracket?

A metal bracket consists of two or more planes at the same edge. To construct a metal bracket, you simply bend a flat piece of sheet metal in two or more points. Generally, metal brackets function as the “middleman” metal component that connects multiple objects while providing structural support.

Where and how are metal brackets used?

Look around you; metal brackets are so common that they are anywhere. A basic example is using a metal bracket to connect a shelf to a wall.

Most metal brackets serve a functional purpose, joining or securing components. As a result, metal brackets are widespread, and you can find examples of their application in fields as diverse as construction, electronics and telecommunications, the automotive industry, dentistry, and even aircraft.

In addition, metal brackets are vital for their respective roles. For example, supporting the roof beams of buildings, connecting the various pieces of furniture, and fastening the electrical components within machine enclosures, to mention a few.

Metal brackets are not only practical, but they also serve as stunning decorative elements.

When using metal brackets for ornamental purposes, we may make them match any colour scheme by polishing or coating them. Some designers even contemplate integrating elaborate patterns or gold plating.

As we know metal brackets better, you will see more examples of metal bracket applications.

How are metal brackets made?

Customized metal brackets go through several stages in production. The first step is the design process. Some of our clients start by providing a computer-aided design (CAD), while others choose to talk with us and discuss the creation of a design blueprint.

Next, we will construct a prototype according to the design concept to acquire a realistic view of the final product. During this stage, we establish which combinations of fabrication methods will help us achieve the metal bracket design in mind. Of course, the complexity and demands of the ultimate product also influence our manufacturing strategy.

Most metal bracket designs involve bending, welding, or even manual fabrication processes. If the great accuracy of the end product is essential, we resort to technologies such as laser cutting and computer-aided manufacturing (CAM) machinery. Once we integrate the CAD outputs into the CAM system, the production of high-accuracy sheet metal manufacturing can happen.

Laser cutting is an efficient and precise way of cutting sheet metal. It is capable of cutting intricate designs with high-speed accuracy. Computer Numerical Controlled (CNC) machining is particularly good at high-precision folding and punching.

For a more in-depth look at how we fabricate sheet metal, check out our earlier piece, “The Overview of Sheet Metal Fabrication.”

What are the common types of metal brackets available?

When it comes to creating metal brackets in real life, the possibilities are endless. Metal brackets are available in various ready shapes, including L-brackets, Z-brackets, U-brackets, and many others. In addition, some metal brackets include mounting holes, while others are threaded or unthreaded. Here are several universal metal bracket styles:

L-bracket: As its name suggests, it is a standard method of fastening a horizontal component to a vertical one and vice versa. The L-bracket has a plethora of different purposes, but one of the most common is to mount shelves to the wall. As a result, the design’s load-bearing capacity depends greatly on the thickness and type of material in use.

Z-bracket: Bending a sheet metal twice produces a bracket resembling the “Z” letter. The Z-bracket is the ideal choice for mounting offset parallel surfaces. The term “parallel” here implies that both surfaces share the same planes in direction, whereas “offset” literally means that they do not overlap perfectly. The Z-bracket is excellent in securing parts at different heights within an enclosure, such as magnetic swing doors.

U-bracket: Metal brackets in the U-configuration are suitable for mounting parallel surfaces together. The distances between adjacent flanges are not random; they are specifically designed to support the component from both sides after assembly.

U-brackets are useful in many situations, such as mounting a power supply or a hard drive.

Offset -bracket: If you imagine a Z-bracket and a U-bracket working together, you have an offset bracket. The offset bracket is a mounting solution like the Z-bracket and a component holder like the U-bracket. In most cases, an offset-lower bracket’s flanges are fastened to the inside of a housing, while the bracket’s upper surface is secure to the part component.

Gusset-bracket: Gussets are an additional piece of metal plates of various thicknesses that joins two or more parts together. Welding gussets onto pre-existing bracket structures reinforces them in most cases.

In addition, the original metal brackets are now sturdier and more durable thanks to adding a new metal piece that increases their rigidity and load-bearing capacity.

Couldn’t find the right solution for your one-of-a-kind project? You can always have a custom-made metal bracket if you need it to fit a specific component or function with a particular surface. It can be a custom enclosure design or a standalone piece.

Thanks to our extensive experience making bespoke metal brackets, NS Metal Fabrication Specialist can produce practically any metal bracket to your specifications.

What materials are suitable for making metal brackets?

Stainless steel: Stainless steel brackets are resistant to corrosion and have good physical qualities. Hence, they are prevalent in high-humidity environments, such as orthodontic applications. In addition, stainless steel brackets also ensure robust construction in building structures.

Aluminium: The aluminium bracket is the most affordable and sturdy of all bracket kinds. It’s also lighter than stainless steel brackets. When lightweight and corrosion resistance are both important, aluminium is an excellent option. In addition, aluminium is receptive to various finishing procedures if you require additional surface treatment.

Galvanneal: The surface of this steel product has a zinc-iron alloy coating as a result of the continuous hot dipping method. Galvanneal has a matte matt grey appearance and does not flake off when forming and bending. The porous surface of galvanneal works well as a foundation for locking in paint components. Galvanneal brackets not only paint well and are anti-corrosive, but they are also excellent for welding and shaping.

Copper: Copper’s distinctive appearance makes it the ideal material for producing a beautiful bracket. Copper brackets are not only aesthetically pleasing, but they are also capable of supporting a fair amount of weight.

In addition, since copper brackets strike a good balance between beauty and functionality, they make wonderful ornamental decors.

Cold-rolled steel: Cold-rolled steel metal brackets are appropriate for general-purpose enclosures. These brackets are inexpensive, highly weldable and rigid, making them an excellent choice for supporting heavy loads. That is why most external air condition units rely on cold-rolled steel brackets as support.

Although cold-rolled steel brackets are susceptible to corrosion in their natural state, adding a powder coating layer will confer additional protection.

What surface is the finishing choices there for my metal bracket project?

Metal brackets must have a standard polish to avoid rust and look good. If you use the metal bracket outdoors or in a humid area, you should have a durable paint job done on the raw steel section. In addition to galvanizing and stainless steel, these other finishing processes provide corrosion resistance:

Powder coat: Powder coating is a dry finishing procedure. It entails applying paint powder on metal surfaces, which undergo electrostatic charging and heat curing. Powder coating is a reliable finishing for industrial equipment, providing uniform and durable coating.

Chemical conversion coating (Chem-film coating): This procedure, also known as yellow chromate coating, applies chromate to a metal substrate. As a result, you can achieve a corrosion-resistant, durable surface with consistent electrical conductivity. Aluminium chassis and components benefit from this coating because it prevents corrosion and allows for secure electrical connections. In addition, it serves as an excellent powder coat preparation.

Masking: When you wish to electroplate your object but preserve some other metal regions, the metal masking technique is a great tool at your disposal. Electroplating metal objects can sometimes lead to dimensional changes or loss of electrical conductivity.

For instance, masking helps maintain the thread size of a threaded bracket. Another scenario is hiding the metal bracket’s electrical contacts so they may continue functioning.

Bare metal finishing: Media blasting (or sandblasting), grained finish, and vibratory finish are all effective methods for de-burring unpolished metal. The end metal product is sleeker and more aesthetically pleasing than before. Metal items with this finishing can go through other processes, such as digital printing, for branding or aesthetic reasons.

Passivation: Passivation comprises citric and nitric acids to remove surface iron from steel surfaces, thus forming a “passive” layer of chromium/nickel oxide. The resulting metal oxide surface coating contributes to the corrosion resistance of existing steel surfaces.

However, some businesses require metal brackets with tight tolerances, or stringent design criteria, making constructing a consistent item challenging. Passivation is particularly useful for achieving tight tolerances and preserving part dimensional integrity.

Anodizing: Anodizing improves the naturally occurring oxide layer on aluminium by using an acid bath and electricity to induce systematic oxidation. This purposeful oxidation process thickens and hardens the oxide surface, increasing its resistance to scratches and abrasion.

Anodized aluminium looks excellent in its natural tone, but you can improve its looks by applying dye with organic dyes to create a variety of colours.

Advantages of using Metal bracket    

Simple installation: Installing metal brackets is much simpler than using screws, especially when it comes to doing so on angled surfaces. You can get by with minimal preparation and standard tools.

Superior support: Because of their limited bearing capacity, screws pose a significant collapse risk when supporting loads that exceed their design specifications.

Metal brackets, particularly those with gussets, are meant to prevent a corner joint from collapsing under great strain resulting from heavy weights or excessive compression. Assuring adequate strength and stability is crucial, making this a top priority.

Versatile: Metal brackets have various applications in different sectors. These range from supporting doors and ceilings to linking frames and braces for structural elements. They can also function as decorative elements on buildings, furniture, and doors. 

Low maintenance: Metal brackets are sturdy and typically built to last. The majority, if not all, of these brackets, have a protective coating to prevent rust and corrosion. Additionally, they are paintable without compromising their longevity.  

Variety of choices and customizable: Metal brackets come in various sizes and designs. Custom metal brackets are available if the available stock options don’t quite meet your specifications. As a broad selection of decorative metal brackets is available, they are a great choice for any interior design theme.

Eco-friendly option: Metal brackets are easily reusable and recyclable. They are eco-friendly and long-lasting since scrap steel can be recycled into new items. As a result, we contribute to reducing waste and the need to mine raw materials.

Conclusion

Metal brackets play crucial functions in many fields and are thus indispensable. The quality and construction of your metal brackets will determine how long they last and how well they function.

We at NS Metal are the go-to experts for fabricating high-quality bespoke sheet metal brackets. If you have an idea, a sketch, a drawing (manual or CAD), or even a solid model, the skilled team at NS Metal can help you bring it to life.

We take great pride in turning our customers’ metalwork concepts into reality through our custom metal fabrication services. Do you have a specific metal bracket design in mind? Then, get in touch to discuss turning your ideas into solutions.

References:

• https://www.3erp.com/blog/guide-to-making-sheet-metal-brackets/
• https://www.theengineer.co.uk/content/product/guide-to-making-sheet-metal-brackets/
• https://www.protocase.com/products/electronic-enclosures/brackets.php
• https://www.shortrunpro.com/content/157-bracket-design-guide
• https://www.rajshiindustries.com/sheet-metal-brackets.html