Custom Chassis Fabrication – Our Process And Added Services

custom chassis fabrication
March 16, 2021

When looking for custom chassis fabrication services, it helps to know the processes and costs involved. Having this information allows you to make an informed decision on the best service for your specific needs. The fabrication of customized structures is a process that requires collaboration in design and precision engineering to produce the desired result with zero margins for error.

For over half a century, New Age Metal Fabricating and New Age Precision Manufacturing have been producing some of the finest precision machined parts for many well-respected companies in the defense and aerospace industries. Because we are a full-service manufacturer, we offer just about every service. We control the timeliness and quality of every product we create, including custom chassis fabrication.

Some of our most popular products are our dip-brazed chassis and enclosures. These are high-money items and, as with all our products, must be precision built. If you are a customer who has tried other suppliers and come away dissatisfied, NAMF and NAPM can get you quality parts delivered on time and for as low a price as possible.

Chassis Design & Fabrication Processes

We construct full chassis all the time. We can make them out of different materials as well as combinations of materials to achieve your desired result. Our engineering team will work with you to help in the designing and building and we are available throughout the creative process.

For those parts and products that we create for the defense and aerospace industry, there is no room for error or inconsistency. The sheet metal fabrication process involves numerous parts – cutting, drilling, punching, welding, forming – all on the strongest metal found on earth.


It all begins with sheets of metal. We cut these into halves, thirds or even smaller sections. In many cases, the metal being shaped is newly made and has acquired no shape to date. There are also pre-shaped metals that we work with for cutting.

New Age Fabricating uses a TruLaser 2030 4 kW Fiber-Optic laser. It can cut 5052, 6061 aluminum alloys, stainless steel, copper, and brass. At NAMF, we have perfected our high-tech machinery to deliver efficiency and precision, time and time again.


Both New Age Metal Fabricating and New Age Precision Manufacturing operate Amada CNC punch presses. These can accommodate sheet sizes up to 50 x 78. Sheet metal punching creates holes in the metal, where the sheet is placed under a die and goes through a punch-through by a drill. Precision is key here and for the punch to be the correct size, the circumference of the drill must slot correctly through the die.


For the most precise custom chassis fabrication, NAMF and NAPM both utilize four CNC press brakes, which can perform a wide range of angles and radii in metals such as aluminum, stainless, copper, and brass.


The process of welding involves the joining of two separate metal parts. These metal parts can be anything – bars, shapes, panels or sheets. All that matters is that they are all metal. In both of our facilities, our precision welding services are performed by our expert welders who are certified to weld to AWS D17.1 and AWS D1.2.

Chemical Conversion Coating

Our added services include chemical conversion coating. New Age Metal Fabricating is NADCAP approved for this process to Mil-Spec Mil-DTL 5541. We offer Type I, classes 1A and 3, and Type II, classes 1A and 3.


New Age Metal Fabricating offers in-house capabilities for wet paint and electrostatic powder coating. We meet the requirements of CARC or Chemical Agent Resistant Coating and we finish all parts in Mil-Specs.

Our Machinery

Chassis fabrication is a multi-staged process that utilizes many types of machinery. From the selection of materials to cutting, welding, and final painting, each stage involves its own assemblage of equipment.

Once a design is final, and our client approves it, we use newly made metal, sometimes pre-shaped if it fits the purpose. To fabricate the components of a project we use the highest quality machinery to ensure the best result.

The first stage may use a laser cutter to cut sheets to size, press brake to create precise angles, and/or a punch that uses CNC (Computer Numerical Controlled) technology. Milling and lathing ensure precision shaping of components before putting them together.

We use a variety of techniques when joining components together. We have the machinery to employ both dip brazing and welding processes. Depending on the shape of the parts themselves, our expert welding specialists use the appropriate techniques to join components efficiently and effectively. Our Paint shop consists of 3 spray booths, a powder coating booth, and a paint baking oven. These guarantee an even, seamless finish that will help protect the metal as well as look great.

chassis fabCosts of Custom Chassis Fabrication

Many types of fabrication can be costly, with sheet metal fabrication for large projects averaging over $2000 in the US. Depending on the scale of the project, the cost of welding can also be high. Especially when it comes to intricate defense and aerospace contracts.

Our engineers work closely with our clients at the design stage. This means we are able to ensure there are no unexpected costs due to miscommunication or errors in the design.

Benefits of Fabrication

There are many benefits of getting a chassis, or any sizeable metal project, fabricated to custom specifications. Firstly, the end product is made specially to your design specifications, meaning you get exactly what you need. Sheet metal, formed into the sizes and shapes you need, is very strong and relatively lightweight. Compared to other metals like cast iron or manganese steel, for example. That being said, another advantage is that you get to choose the material you want to use for your project. Not only that, but it’s also highly durable and resistant to heat and corrosion.

Another benefit is that the people involved in the fabrication process must be highly qualified and experienced. This means you can trust that your design will be brought to life by the best people for the job.

Industries that use custom chassis fabrication are many and varied. These include:

  • Manufacturing. Here you will find architectural and structural metals, boiler, tank and shipping containers, spring and wire products, and specialty manufacturing.
  • Hardware and Hand Tools. Included here is hardware manufacturing for computer parts and components, modems, monitors, cutlery and hand tools, turned product and screw, nut and bolt manufacturing.
  • Building and Construction. This is where you find the HVAC industry and the building and construction industry.
  • Farming Industry
  • The Aerospace Industry. There are various items consisting of metal fabricated parts, which have been manufactured by aircraft developers. Aerospace is one of the most concise and demanding industries when it comes to safety.

Custom Fabrication At It’s Best

If you have a design that you need to be fabricated with your exact specifications in mind, get in touch. With our team, you can start and finish your project with the best people in the business.

At New Age Metal Fabricating and New Age Precision Manufacturing, we are proud to serve both the defense and aerospace industries with our complete custom chassis fabrication services. For over half a century, New Age Metal Fabricating in New Jersey and New Age Precision Manufacturing on Long Island, NY have been offering the most advanced and cutting-edge manufacturing technologies and techniques to meet the ever-changing needs of our customers.

Because we are a single-source supplier of precision manufactured and dip-brazed products, we can offer you complete, turnkey solutions for all of your material purchasing needs. We save you time and money, including the expense of having to finding multiple suppliers to finish your job. We do it all right in our facilities.

We would like you to join our list of satisfied customers for all of your metal fabrication needs, including custom chassis fabrication. Browse our website and then contact us today. We look forward to the challenges you will bring us.