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How to Fabricate a Sheet Metal Cone: A Comprehensive Guide

Sheet metal cones are versatile and essential components in various industries, including construction, HVAC, automotive, and aerospace. They serve a wide range of functions, from decorative elements to structural supports and ductwork. In this comprehensive guide, we will take you through the process of fabricating a sheet metal cone from start to finish.

Materials and Tools You'll Need

Before we dive into the fabrication process, let's gather the necessary materials and tools. To fabricate a sheet metal cone, you'll need:

Sheet metal (preferably steel, aluminum, or copper)

A compass or a large piece of string

Tape measure

Straight edge or ruler

Metal cutting shears or a plasma cutter

Metal file or deburring tool

Welder (MIG, TIG, or oxy-acetylene)

Welding gloves, helmet, and other safety gear

Hammer and dolly (optional)

Step 1: Determine the Cone Dimensions

First, you need to determine the dimensions of the cone you want to fabricate. This includes the base diameter, top diameter, and height. If you're working with a specific design or blueprint, these dimensions should be provided. Otherwise, you can determine the dimensions based on your project's requirements.

Step 2: Calculate the Cone's Development

The development of a cone is the flattened, two-dimensional representation of the cone's surface. To calculate the cone's development, you'll need to determine the following parameters:

Slant height (L): This is the distance from the top of the cone to the edge of the base, measured along the cone's surface. You can calculate the slant height using the Pythagorean theorem: L = √(H2 + R2), where H is the cone's height, and R is the base radius.

Arc length (C): This is the length of the curved edge of the cone's development, which corresponds to the circumference of the cone's base. To calculate the arc length, use the formula C = 2πR, where R is the base radius.

Central angle (θ): This is the angle at the center of the cone's development, which determines the shape and size of the cone. The formula for the central angle is θ = (360 \C) / (2πR).

Step 3: Draw the Cone's Development

Using a compass or a large piece of string, draw a circle on the sheet metal with a radius equal to the slant height of the cone. Then, draw a straight line from the center of the circle to the edge, representing the cone's height.

Next, measure the arc length along the circle's circumference and mark the endpoints. Draw a second straight line from the center of the circle to the second endpoint, creating a sector with a central angle equal to the calculated value. This sector represents the cone's development.

Step 4: Cut and Deburr the Sheet Metal

Carefully cut along the lines of the cone's development using metal cutting shears or a plasma cutter. Make sure to wear appropriate safety gear and follow the tool's guidelines for safe operation.

After cutting the sheet metal, use a metal file or deburring tool to smooth the edges and remove any burrs or sharp edges. This will ensure a clean and safe working environment and reduce the risk of injury during the fabrication process.

Step 5: Form the Cone

Align the straight edges of the cone's development, forming the cone shape. You may need to use a hammer and dolly to gently shape the metal, especially if you're working with thicker gauge material. Ensure that the edges are properly aligned and that the cone's dimensions match your original specifications.

Step 6: Weld the Seam

Once the cone is formed, it's time to weld the seam. Depending on your skill level and the material you're working with, you can choose between MIG, TIG, or oxy-acetylene welding. Make sure to wear proper safety gear, including a welding helmet, gloves, and protective clothing.

Start by tack welding the seam at several points to secure the cone's shape. Then, weld the entire length of the seam, ensuring a strong and clean weld. After the weld has cooled, use a metal file or grinder to smooth the weld and blend it with the rest of the cone's surface.

Step 7: Inspect and Finish the Cone

After the welding process is complete, inspect the cone for any defects or inconsistencies. Check the dimensions and shape to ensure they meet your project's requirements. If necessary, use a hammer and dolly to make any minor adjustments to the cone's shape.

Finally, clean the cone's surface and apply any necessary finishes, such as paint or protective coatings. Your sheet metal cone is now complete and ready for use in your project.

In this guide, we've covered the essential steps for fabricating a sheet metal cone. With the right tools, materials, and a bit of practice, you can create custom sheet metal cones tailored to your specific needs and applications. Happy fabricating!

how to fabricate a sheet metal cone

What is Sheet Metal Fabrication

Sheet Metal Fabrication is the process of forming metal sheets into structures or parts using various techniques such as cutting, bending, and welding.

This process commonly use for products such as car parts, building materials, and household appliances.

The sheet metal is often cut to size and holes using a shearing machine or laser cutter, and then bent into shape. Once the parts formed, they are typically welded, riveted, or fastened together to create the final product.

Sheet Metal Fabrication Service

Asianstar Professional Sheet Metal Fabrication

Sheet Metal Fabrication Service

Asianstar Company Sheet Metal Fabrication provides a range of services to clients.

We have machines involves Cutting, Bending, Punching, Drilling, Welding and Forming, we also have hand-tool to make samples of sheet metal fabrication samples in rapid reaction.

With our skillful engineers and tools, we are able to provide complicated structure sheet metal components, and then apply surface finishing treatment on components and support clients to assemble the final products.

For huge quantities sheet metal fabrication demands, we use our own CNC Machines to open tooling or mold for sheet parts, with our in-house facilities supporting, we can carry perfect result on the structure and productivity.

Asianstar: Professional CNC Machining Supplier

From year of 2005, Asianstar Company establish the CNC Machining Factory in Guangdong Province, China.
We mostly provide CNC Turning, Milling, Drilling, Grinding, and Multi Machining processes service on various materials.
With the Belief of becoming a key supplier in the supply-chain of Precision Components, we strictly control our product quality, keep high precision on our components production, buildup the whole-process QC System and submit the satisfaction for every order.
By long term development, we have buildup partnership with world-wide clients, supporting our partners in Designing, Optimizing, Producing and Testing on each type of components.


Multiple Machining Processes

Multiple Machining Processes

Asianstar has various machining processes to support different types of components from client, we can choose the best suitable manufacturing solution to carry result in perfect performance and cheap cost

Flexible Custom Service

Flexible Custom Service

With skillful machining technologies, Asianstar is flexible to support clients on different materials and different structures of the components, we also flexible on the components quantities and even assembly

Create Designing for Clients

Create Designing for Clients

Not only producing according to clients drawings, Asianstar also propose the better designing to clients, supporting clients to buildup improved designing or even new generation components

Standard Procedures

Standard Procedures

Asianstar production, as experienced by many years, is strictly following internal Standard Operating Procedures, to make sure the production schedule is smooth and plans are well carried out well without accidents

Standard Procedures

Standard Procedures

Asianstar strictly controlling product quality by system. We start QC controlling from production plan once setting up, to production process by monitoring QC checking and until the final Inspection before packing

Fast Lead-Time Delivery

Fast Lead-Time Delivery

Asianstar strictly control the production processes, teams keep the plan moving ahead according to the procedures, we have internal time management schedule which mostly bring earlier lead-time of delivery


CNC Turning Service

CNC Turning Service

Our CNC Turning Service provides different sizes of roll shape work-pieces, the diameter range is from 0.5mm to 480mm, reaching tolerance +/-0.003mm.

CNC Milling Service

CNC Milling Service

Our milling machines and CNC centers are able to produce complicated structure part, five-axis devices produce multi-sides at one-time jag which bring high precision result

Sheet Metal Fabrication

Sheet Metal Fabrication

Our Sheet Metal Fabrication provides slicing, punching, bending, welding, painting and assembling for set products, unique tooling for each project to raise production efficiency

Aluminum Extrusion

Aluminum Extrusion

Our Aluminum Extrusion brings clients various shapes of aluminum parts, high efficiency for mass quantity, our precision extrusion mold control tolerance within 0.01mm

Forging Service

Forging Service

For some steel serious products, we apply Forging Service to make out their outer shape and them use CNC devices to start drilling, forming, rolling, cutting, etc.

Finishing Service

Finishing Service

Our Surface Finishing Service uses chemical or electro post-treatments after machining tasks are finished, normally includes Oxide, Anodizing, Passivation, E-Plating, Painting,etc.


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