Sheet Metal & Custom Ductwork Fabrication In Spearfish, SD
At Western Edge Metals, we take pride in producing precision-built sheet metal and HVAC ductwork for contractors, builders, and HVAC professionals across Spearfish and the Black Hills region. Our in-house fabrication shop in Spearfish, SD combines modern technology with hands-on craftsmanship — ensuring every piece is shaped, welded, and fitted to exact specifications. From residential duct fittings to large commercial air systems, every project is made to perform efficiently and last for decades.
Our experienced metal fabricators specialize in custom ductwork, plasma cutting, forming, and welding, delivering dependable components built for real-world performance. We use high-quality materials, proven fabrication methods, and a commitment to safety that ensures your installation meets code, runs quietly, and stands the test of time.
Custom Metal Fabrication for HVAC Professionals & Contractors
We’ve been in the industry for nearly 20 years and know that no two HVAC systems are exactly the same — and that’s where Western Edge Metals makes the difference. Our proven custom sheet metal fabrication service tailors every duct, plenum, transition, and fitting to your exact needs. Whether you’re designing a new commercial HVAC system or replacing outdated ductwork in an existing structure, our fabricators work closely with your plans to ensure a perfect fit and optimal airflow.
We fabricate components for a wide variety of applications, including:
Commercial HVAC systems
Residential ductwork and venting
Industrial ventilation and exhaust systems
Custom metal parts and enclosures
Specialty fittings and transitions
With each project, our goal is simple — create a system that moves air efficiently, reduces energy waste, and helps your equipment perform at its best.
Precision-Built Ductwork That Improves System Efficiency
Properly fabricated ductwork is the foundation of an efficient HVAC system. Poorly joined or undersized ducts can lead to energy loss, noisy operation, and uneven temperatures. Our technicians use computer-guided plasma cutting and precision forming equipment to ensure airtight seams and smooth airflow paths. This means your heating and cooling equipment doesn’t have to work as hard — saving energy, improving performance, and extending system life.
Every job is completed under the supervision of seasoned professionals who understand both the science of air movement and the art of metal fabrication. That combination results in products that look professional, install cleanly, and perform exactly as intended.
Frequently Asked Questions About Sheet Metal & HVAC Ductwork Fabrication
1. What is sheet metal fabrication used for in HVAC systems?
Sheet metal fabrication is used to create the ducts, fittings, and components that move air through heating and cooling systems. Each piece is cut, bent, and joined to fit the system layout, ensuring efficient airflow, durability, and quiet operation.
2. What type of metal is best for HVAC ductwork?
The most common material for HVAC ductwork is galvanized steel because it resists rust and corrosion while maintaining structural strength. In some cases, aluminum or stainless steel is used for specialized applications such as industrial exhaust or high-moisture environments.
3. How is HVAC ductwork fabricated?
Ductwork fabrication involves cutting sheet metal into specific sizes and shapes, then forming and joining the pieces with machines like plasma cutters, brakes, and seam welders. Modern fabrication shops use computer-guided tools for precise, leak-free results that improve system efficiency.
4. Why is custom ductwork better than prefabricated ducts?
Custom ductwork is built to fit the exact dimensions and airflow requirements of a building. Unlike prefabricated ducts, which may require on-site adjustments, custom-fabricated ducts provide a perfect fit, reducing air leaks, improving energy efficiency, and ensuring balanced airflow throughout the system.
5. What factors affect the cost of sheet metal fabrication?
Costs depend on material type, thickness, project size, labor, and complexity. Stainless steel or insulated ductwork, for example, costs more than standard galvanized steel. Precision cutting, welding, and finishing can also add to fabrication time and price.
6. How does duct design impact HVAC system performance?
The design of ductwork directly affects how efficiently air moves through a system. Poorly designed ducts can lead to hot and cold spots, higher energy bills, and premature equipment wear. Properly fabricated ducts with airtight seams and smooth bends help maintain consistent airflow and comfort.
7. What’s the difference between rectangular and spiral ductwork?
Rectangular ducts are often used in tight spaces or commercial buildings, while spiral (round) ducts are preferred for open areas or industrial applications. Spiral ducts are typically more energy-efficient because their shape reduces air turbulence and pressure loss.
8. How thick should sheet metal be for ductwork?
The thickness of sheet metal, known as gauge, depends on the duct size and system pressure. Residential ducts often use 26–30 gauge metal, while commercial systems may use 20–24 gauge for added strength and durability.
9. How do leaks in ductwork affect HVAC efficiency?
Air leaks in ductwork can waste 20–30% of a system’s energy output. They reduce airflow, make equipment work harder, and cause uneven temperatures. Precision fabrication and professional installation are key to preventing leaks and improving energy performance.
10. What maintenance does metal ductwork require?
Metal ductwork should be inspected every few years for dust buildup, corrosion, or loose connections. Cleaning and sealing leaks helps maintain good indoor air quality and system efficiency. High-quality fabricated ducts typically require minimal maintenance over their lifespan.
11. What are the most common metals used in sheet metal fabrication?
Common materials include galvanized steel, stainless steel, aluminum, and copper. Each metal has specific advantages — for example, galvanized steel is cost-effective and durable, while stainless steel resists corrosion in harsh environments.
12. How do modern fabrication shops ensure precision in ductwork production?
Many fabrication shops now use CNC plasma cutters, computer-aided design (CAD), and automated forming machines. These tools ensure every piece is made to specification, reducing human error and improving installation accuracy on the job site.
13. How does proper duct fabrication improve indoor air quality?
High-quality fabricated ductwork reduces air leakage and prevents contaminants from entering the airflow. Smooth interior surfaces minimize dust buildup, helping HVAC systems deliver cleaner air and more consistent temperatures throughout the building.
14. What certifications or safety standards apply to sheet metal fabrication?
Fabrication and installation often follow SMACNA (Sheet Metal and Air Conditioning Contractors’ National Association) standards and ASHRAE guidelines. These standards ensure the ducts meet safety, performance, and efficiency requirements for residential and commercial systems.
15. What’s the lifespan of metal ductwork?
Properly fabricated and maintained metal ductwork can last 30 years or more. Factors like humidity, air quality, and insulation can impact longevity, but quality fabrication and sealed connections significantly extend the system’s life.