How Much Does Metal Fabrication Cost — Typical Prices, Factors and Quick Estimates

Wondering how much metal fabrication will cost your project? Expect a broad range: simple parts can run from tens to a few hundred pounds, while complex assemblies often cost several thousand, with material choice, labour, and precision driving the price. You can narrow that range quickly by defining size, material and finish requirements.

You’ll save time and money by knowing the main cost drivers up front — material type, cutting and forming methods, welding and surface treatment, and tolerances. Start with a clear spec and a few quotes to compare real-world prices.

Steel master fabricators recommend getting clear specifications and multiple quotes from a trusted Metal fabricator to control costs.

Key Takeaways

• Costs vary widely depending on materials and complexity.

• Labour processes and precision significantly affect the final price.

• Get clear specifications and multiple quotes to control costs.

Key Factors Affecting Metal Fabrication Cost

Material type, labour skill, design complexity and production volume determine most of your fabrication expenses. Each factor affects unit cost, lead time and quality in different ways.

Material Selection and Pricing

Your material choice drives both direct cost and downstream processing expenses. Common options include mild steel, stainless steel, aluminium, and specialised alloys; mild steel costs less per kg but may need corrosion protection, while stainless resists corrosion but costs 2–4× more depending on grade.

Thickness and form (sheet, plate, bar, tube) influence waste and cutting time. Thicker sections increase machining and welding labour and require heavier press brakes or CNC plasma/laser settings, raising machine-hour costs. Surface finish and certification (e.g. EN or ASTM mill test reports) add premium pricing and traceability fees.

Market volatility and scrap value affect quotes; you should lock pricing with suppliers for large orders. Supply chain lead times for exotic alloys can add holding costs and delay production.

Labour Costs and Skill Levels

Labour forms a large portion of your fabrication bill, especially for welding, assembly and finishing. Skilled TIG welders and CNC programmers command higher hourly rates but reduce rework and improve yield; unskilled labour lowers hourly cost but raises scrap and inspection needs.

Shop location and local wage standards change overheads; metropolitan workshops often cost more per hour than regional shops. Labour cost models should include training, certification, supervision and overtime premiums.

Productivity depends on equipment support: automated welding cells and robotic handling lower per-unit labour as volume rises.

Design Complexity and Customisation

Complex geometry, tight tolerances and multiple assemblies increase fabrication time and inspection requirements. Features like compound bends, internal cutouts, and precision dowel locations need skilled programming, specialised tooling and jigging, all of which add setup and fixture costs.

Custom one-off pieces incur higher engineering hours for CAD modelling, CAM programming and prototype validation. Standardised designs reduce setup by enabling repeatable fixtures and NC programs. Tight tolerances (e.g. ±0.1 mm vs ±1.0 mm) increase machining and measurement costs considerably.

Finish requirements such as powder coating, galvanising or passivation add processing steps and handling. Design for manufacturability (DfM) can cut costs by simplifying joins, using standard fasteners and minimising secondary operations.

Production Volume and Batch Size

Your batch size directly affects unit cost through setup amortisation and economies of scale. Small batches and one-offs carry high per-unit setup, inspection and engineering overheads. Large runs spread fixture, programming and tooling costs across many parts, reducing unit price.

Lead time expectations influence batch strategy; rush orders for small batches can trigger premium shipping, overtime and expedited material sourcing. Consider MOQ from vendors and machine changeover time when planning lots.

Where demand fluctuates, balance inventory carrying costs against frequent small runs to find the lowest total cost per part.

Price Breakdown and Additional Considerations

Expect equipment setup, finishing choices, and delivery logistics to shift your quote by hundreds to thousands of pounds. Each line item—tooling, coatings, transport—affects lead time and final cost of a metal fabricator, so check specifics on materials, quantities and tolerances before committing.

Equipment and Tooling Expenses

Tooling covers bespoke dies, CNC programmes, laser nesting files, jigs and welding fixtures. You pay a one‑off fee for custom tooling that typically ranges from £100 for simple jigs to £5,000+ for complex press tools or progressive dies.If you order repeat batches, amortise tooling across units: 1,000 parts reduces per‑piece tooling cost far more than 10 parts. Ask suppliers whether they charge separately for CAD/CAM setup and proofing samples; those often add £50–£500.

Machine time and setup labour also matter. Laser cutting, bending and CNC work are billed by machine hour or minute; expect £40–£120/hr for CNC work and £30–£90/hr for laser cutting in the UK. Tight tolerances or small batches increase setup-to-production ratio, driving per‑unit costs higher.

Finishing and Surface Treatments

Finishes include galvanising, powder coating, anodising (for aluminium), wet paint and shot blasting. Powder coating normally costs £8–£25/m² depending on colour and thickness; galvanising is often £2–£8/kg extra. Provide required salt‑spray hours, gloss level and colour RAL to get accurate quotes.Complex geometries or internal cavities may need additional masking, which incurs labour and material costs of £0.50–£3 per masked feature.

Specialist post‑treatments such as chemical passivation, electropolishing or decorative plating raise costs substantially. Expect an extra 10–50% on top of base fabrication for these processes. Always confirm whether prices include testing (adhesion, thickness) and waste disposal fees.

When looking for a reliable Metal fabricator, Steel master fabricators can provide detailed quotes and advice on all aspects of your project. Choosing an experienced Metal fabricator like Steel master fabricators ensures you get the best value and quality for your metal fabrication needs.

You may also find our blogs “What do metal fabricators do” and “Metal fabricators and installers” useful for understanding services, responsibilities, and how projects are delivered from start to finish.

Delivery and Installation Charges

Transport pricing depends on weight, size and access. Palleted fabrications under 2 m typically ship by courier or pallet network for £20–£150. Oversize or heavy items require tail-lift or HIAB and can cost £200–£1,200+ per delivery.Site access constraints—narrow lanes, low bridges, or restricted hours—often add waiting or unloading charges. Ask Steel master fabricators, your trusted Metal fabricator, for confirmed lift and access specs to avoid on‑site surcharges.

Installation labour is commonly quoted separately and billed by time and skill level. Expect £40–£80/hr for experienced site welders or fitters in the UK, plus travel and safety equipment. Request line‑item estimates for mechanical fixing, alignment, and testing from Steel master fabricators so you can compare Metal fabricator suppliers directly.