SMLease Design

Mechanical Product Design & Development Partner

How To Join Sheet Metal Parts

There are several options like screws, rivets, welding, adhessive, Clinching / tox round joint, folding, are some of commonly used sheet metal parts joining techniques. Selection of best process for joining sheet metal parts depends on the material, its thickness and application.

This guide will give you an overview of the techniques used to join / assembly sheet metal parts

You can contact us for mechanical design services and for any support related to sheet metal assembly process design, sheet metal part design.


Screw Joints

Screws are most commonly used method to make removable joints between two sheet metal parts. Self-Tapping sheet metal screws and machine screws are used to join sheet metal parts.


Self Tapping Sheet Metal Screws

This is most economical way of joining sheet metal parts with screws. Except pilot hole that is done during punching process, no additional operation and fastener is required with self tapping screw.

Selection of size of screw is done depending on material and material thickness. If thickness of sheet metal part is less, overlapping of screw on sheet will be less that will not make a strong joint. To increase screw overlap extruded hole can be added.  


Machine Screws

Machine screws are one the most common way to make removable joint between two sheet metal parts. Along with machine screw generally a threaded fastener (clinched, Riveted, welded) is used to make a blind joint between two sheet metal parts.

This approach also increases overall cost to some extent but on other side it help it making overall product assembly easy. 

Selection of type & size of screw, Type of threaded fastener is done based on material to be assembled, sheet thickness, approach to be used for assembly and overall forces acting on parts.



Rivets Joints

Riveting is an operation of joining two plates with the help of a rivetHoles are punched in two sheet metal plates to be joined and then rivet is inserted.  Adequate mechanical force is applied to make the joint strong and leak proof.  Rivets are used to make permanent fastening joint between two sheet metal parts. 

Different types of rivets like Solid, Semi-tubular, oscar, drive, Blind / Pop & Flush rivets are available.

But in sheet metal mostly Blind/Pop rivets with CSK or Round head is used. Blind rivets are inserted into drilled holes in the parts to be joined, and a special tool is used to draw the mandrel through the body of the rivet. The blind end expands, and the mandrel is snapped off. Compared to solid, blind rivets can be installed in joints from only one side of the part making them “blind” to the opposite side. 



Clinching Joint

Clinching is a joining technique for two sheet metal parts with different thickness & material using cold forming process.

Clinching is a simple joining technique that does not required additional fasteners. Clinching process produces a button-type, positive connection of two or three layers of sheet metal using a cold-forming process.


Check out in detail about Clinching joint here :




Welding Joints

Welding is one of the commonly used process for permanently joining sheet metal parts. Seam welding is done in Sheet Metal parts to achieve water/air tight joints.

Type of welding selection for an application depends on material to be joined, sheet thickness, required finish and product application. Following are the commonly used welding in sheet metal parts.

  • TIG Welding
  • MIG Welding
  • Spot Welding
  • Seam Welding



Folding / Tab Joints

Folding & bending tabs is one of the most economical way of making permanent strong joints in sheet-metal parts. This process requires no fastening hardware. Only forming machine is required to make joint

The metals most commonly joined using tabs are soft steel, aluminium, copper, and brass.


If you need any help related to sheet metal assembly & part design, you can contact us for any kind of mechanical design services

Go Back



Latest Posts

Page Counter