Metal Offcuts – Comprehensive Materials Guide

Introduction

Choosing the right metal for your project is crucial to achieving the best results. Whether you need a durable material for industrial applications, a decorative metal for design projects, or a versatile option for DIY crafting, this guide is divided into seven sections, and remember,  all our custom cut and cut-to-size sheets are always from new sheets, not offcuts unless it says “special offers”:

✅ Aluminium
✅ Copper
✅ Brass
✅ Stainless Steel
✅ Zinc
✅ Corten
✅ Pewter

It provides an easy-to-read overview to help you understand the basic properties, uses, and workability of each metal available at Metal Offcuts. Along the way, you’ll pick up useful tips and tricks to help with your project.

Many of our metals come with a protective peelable film on the face side to help prevent scratches during handling and transport. We also offer free cutting services for all purchases from the online store (enter sizes as you check out), ensuring you get the exact size you need for your project.

If you need assistance or a custom quotation? Contact us via our Enquiry Form.

Aluminium Sheet

Properties:

• Eight Series of Aluminium Alloys are Classified from 1000 to 8000 series.
• Grade 1050 Aluminium – 99% pure aluminium, widely used for general-purpose fabrication.
• Lightweight & Strong – One-third the weight of steel with a relative density of 2.7.
• Corrosion-Resistant – Grade 1050 is used in construction, while Grade 5754 is ideal for marine applications (boat decks, ramps).
• Easy to Work With – Can be cut, drilled, and shaped using standard tools.
• Non-Magnetic – Suitable for applications where magnetism needs to be avoided.

Common Applications:

• DIY & Crafting: Used in home, garden, vehicle, and boat projects.
• Signage & Displays: Ideal for lightboxes, display boards, and shop canopy systems, often powder-coated to match branding.
• Kitchen Splashbacks: Popular in anodised or checker plate finishes, frequently used in mobile cafés.
• Industrial Components: Found in countless applications across multiple industries.

Finishes Available:

• Natural Aluminium – Semi-bright finish from the rolling mill. Grade 1050
• Mirror Polished Aluminium – Features a bright, shiny finish (has a slight grain). Grade 1050
• Brushed Aluminium – 240-grit finish, dull polished with a visible grain. Grade 1050
• Checker Plate Aluminium – 5-bar pattern for slip resistance. Grade 5754
• Stucco Aluminium – Embossed texture for decoration and added rigidity. Grade 1050
• Anodised Aluminium – Satin silver finish decorative and durable. (This is a 5000 series aluminium)

Workability:

• Cutting & Drilling:
  • Aluminium is easily cut and drilled using standard tools.
  • HSS blades and drill bits work well.
  • When drilling by hand, apply light pressure and gradually increase hole size.
  • Use a centre punch to prevent drill bits from skidding.
  • If using a pedestal drill, select the appropriate speed and lubrication for a clean cut.
• Folding & Shaping:
  • 0.5mm bends easily by hand, ideal for DIY projects like camping stove draft screens.
  • 1.2mm can be hand-bent with timber clamps or a vice.
  • 1.5mm and above require industrial tools for clean bends.
  • Hand folders work up to 2.0mm, while 3.0mm+ is best formed using a folding machine.
  • Grade 5754 (check plate) is springier than 1050, making it harder to fold.
  • Professional workshops typically use press brakes for precise bends.
• Welding & Painting:
  • TIG, MIG, and laser welding are suitable, but thin aluminium sheets can be tricky to weld.
  • Metal Offcuts provides TIG and MIG welding services for sheets 1.5mm and thicker.
  • Painting: Aluminium should be degreased and free of contaminants before applying an etch primer and topcoat.

Care & Maintenance:

• Low Maintenance: Indoors, aluminium retains its appearance. Outdoors, consider painting or using anodised finishes, which only require occasional cleaning with soapy water and a microfiber cloth.
• Checker Plate Aluminium: Rarely painted, as it retains its appearance long-term.
• Mirror-Polished Aluminium: Protect from scratches. Clean with Mr Sheen or similar polishes, and if needed, repolish using Brasso and a microfiber cloth.
• Brushed Aluminium: Mainly for indoor decorative use. Mr Sheen will slightly reduce reflectivity.
• Storage: Always keep aluminium sheets dry. Water ingress between sheets or pooling on the surface can cause white rust, affecting appearance.

Copper Sheet

Properties:

• Highly Malleable & Easy to Shape: Copper is an exceptionally workable metal, making it ideal for a variety of applications.
  • 0.4mm – Very flexible, can be moulded into intricate shapes.
  • 0.5mm – Still bendable by hand.
  • 0.7mm – 0.9mm – Stiffer but can be shaped with hand tools.
  • 1.2mm – Holds its shape well and remains stable up to 1 meter in height.
  • 1.5mm – 3.0mm – Used for general sheet metal work, requiring folders or press brakes for bending.
• Commonly Stocked Grades:
  • C101 & C103 Copper – Primarily used for electrical applications such as busbars. Often used for general fabrication.
  • C106 Copper – The go-to choice for general fabrication, stocked in gauges up to 1.5mm at Metal Offcuts.
• Natural Patina Formation:
  • Copper naturally ages and develops a patina, transitioning from bright reddish tones to deep brown or verdigris green over time.
  • Patinas can be controlled to achieve custom finishes.
• Antimicrobial Properties:
  • Copper is one of the few naturally antimicrobial metals, reducing bacteria and viruses on touch surfaces.
  • Used in kitchen worktops, bar tops, and door handles for hygienic benefits

Common Applications:

• Kitchen Splashbacks – Popular in industrial and rustic designs, left to age naturally or lacquered for a preserved finish.
• Worktops & Bar Tops – Frequently used in hotels, restaurants, and pubs.
• Decorative Wall Cladding – Ideal for feature walls and artistic installations, with natural or patinated finishes.
• Crafting & Engraving – Copper ages beautifully, making it an excellent choice for signage, jewellery, and decorative pieces.
• Architecture – Roofs, Cladding, Facades, Gutters, Flashings

Finishes Available:

• Natural Copper – Semi-bright finish.
• Brushed Copper – Dull, satin finish with a grain along the sheet.
• Mirror Polished Copper – Bright and highly reflective.
• Hammered Copper – Available in polished finish hand-hammered 0.7mm thick. 
• Aged & Antique Patinated Copper – Designed for warm, rustic tones, widely used in interior décor and industrial themes.

Workability:

• Cutting & Drilling:
  • Easily cut with standard tools such as shears, guillotines, and jigsaws.
  • Drilling is straightforward with HSS drill bits.
• Joining Methods:
  • Soldering, TIG welding, and brazing are the most common joining techniques.
  • For DIY & crafting thin sheets, soldering is the simplest method – use a high-quality tin/silver pre-fluxed solder.
  • A 200W soldering iron is recommended for 0.9mm or 1.2mm sheets. Preheat with a hot air gun.
  • TIG welding is best for thicker copper, though it requires skill to avoid distortion.
  • Always clean the joint before soldering or welding to remove oxidation and ensure a strong bond.

Care & Maintenance:

• Patina Development:
  • Copper will naturally darken and develop a rich patina over time.
  • If a custom patina is desired, various formulas can be applied to achieve different colours and effects.
• Cleaning & Polishing:
  • To maintain a bright mirror finish, use Brasso or a similar cleaner.
  • Wash with mild, soapy water and a microfiber cloth, then dry immediately.
  • Avoid abrasive kitchen cleaners, as they can damage the surface.
• Protective Coatings:
  • Clear polyurethane lacquers can be applied to seal the surface.
  • Wax coatings provide a degree of protection while maintaining a natural finish.
  • Copper bonded to glass is a great option for preserving the pristine look while protecting the surface.

 

Brass Sheet

Properties:

• Strong & Durable: Brass is a copper-zinc alloy known for its strength and versatility.
• Commonly Stocked Grades:
  • CZ108 Brass – The most commonly used grade, ideal for general-purpose applications.
  • CZ120 Brass – Easier to machine than CZ108, preferred for engraving.
  • CZ106 Brass – A softer brass used for spin-forming applications, such as sinks, bowls, and tabletops.
• Naturally Corrosion-Resistant:
  • Brass develops a self-protecting patina over time, transitioning to a dark brown or black finish in outdoor environments.
• Decorative Golden Appearance:
  • Brass is widely used in luxury design due to its gold-like aesthetic.

Common Applications:

• Engraved Plaques & Signage – Used for front door signs, commemorative plaques, and industrial nameplates.
• Decorative Furniture Panels – Adds an elegant touch to furniture, inlays, and accent pieces.
• Architectural Features – Found in door furniture, handles, letterboxes, and signage, as well as bathroom fixtures, light fittings, and vanity mirrors.
• Musical Instruments – Essential for brass wind instruments such as trumpets, trombones, and tub
• Hospitality – Interior decor features like bar tops, table tops, kitchens, reception areas

Finishes Available:

• Natural Brass – Semi-bright finish; thinner sheets tend to appear brighter than thicker ones.
• Mirror Polished Brass – Highly reflective, commonly used for ornamental applications.
• Brushed Brass – Soft satin finish with a linear grain.
• Hammered Brass – Textured surface for a handcrafted, vintage look.
• Engraving Brass  – Natural semi bright finish
• Aged & Antique Patinated Brass – Designed for classic, period-style aesthetics.

Workability:

• Cutting & Drilling:
  • Brass can be easily cut and drilled with standard tools such as shears, saws, and CNC routers.
  • HSS drill bits work well for drilling.
• Bending & Shaping:
  • More rigid than copper, but still highly workable.
  • Hand bending works for thinner sheets (up to 0.5mm), but thicker sheets may require industrial tools.
• Joining & Finishing:
  • Brass can be soldered, brazed, or TIG welded, depending on thickness and application.
  • Lacquering helps maintain a polished or patinated finish.

Care & Maintenance:

• Tarnishing & Patina Development:
  • Brass naturally oxidises over time, creating a darker patina.
  • To maintain brightness, use Brasso or a similar metal polish.
• Cleaning:
  • Wash with warm soapy water and a microfiber cloth to remove dirt.
  • Avoid abrasive cleaners, as they may scratch the surface and affect the finish.
• Protective Coatings:
  • Polyurethane lacquer can be applied to reduce tarnishing and keep a consistent finish.

 

Stainless Steel Sheet

Properties:

• Highly Durable & Corrosion-Resistant: Stainless steel is known for its exceptional strength and longevity.
• Commonly Used Grades:
  • Grade 430 Stainless Steel (1.4016) – A basic stainless steel, magnetic, and suitable for indoor applications where moderate corrosion resistance is acceptable.
  • Grade 304 Stainless Steel (1.4301) – The most common food-grade stainless steel, known as 18/8 stainless (18% chromium, 8% nickel).
  • Grade 316 Stainless Steel (1.4401) – Marine-grade stainless steel, offering high corrosion resistance, often used in surgical, food processing, and marine applications.
• Corrosion Resistance Ranking: 430 < 304 < 316 (higher resistance also means a higher price).
• Hygienic & Easy to Clean: Stainless steel is naturally stain-resistant and can withstand aggressive cleaning agents without damage.
• High Strength & Rigidity: More challenging to fabricate than aluminium due to its hardness and high tensile strength.

Common Applications:

• Kitchen Equipment & Splashbacks – Ideal for food-safe environments. 430 is used for economy, and 304 is an upgrade, especially if aggressive cleaners are used. Grade 430 stainless is magnetic, making it an excellent choice for magnetic notice boards.
• Catering – Grade 304 is extensively used for areas in contact with food and 430 for display equipment.
• Industrial & Commercial Use – Used in food processing, chemical equipment, and hospital/medical facilities.
• Architecture – Building features like cladding, sun screens, features
• Decorative Wall Cladding – Found in modern architecture, often using patterned or perforated stainless sheets. Also used for safety mirrors.
• Automotive & Aerospace – Used in trim details, engine components, and high-performance parts.

Finishes Available:

• Mirror Polished Stainless Steel – Available in two types:
  • Chemically Polished – Flawless, highly reflective surface. This is our standard stock.
  • Mechanically Polished – Slight grain visible upon close inspection.
• Brushed Stainless Steel – Available in 240 grit in 304 and 430 grades, 304 is a little more reflective and smoother.
• Patterned Stainless Steel – Includes textures such as 5WL, 6WL, and Squares, among others.
• Perforated Stainless Steel – Available in hole diameters from 1mm to 10mm.

Workability:

• Cutting & Drilling:
  • Requires specialist tools due to its hardness.
  • Cobalt drill bits are recommended for stainless steel.
  • Drilling should be done at slow speeds with lubricant to prevent overheating.
• Shaping & Folding:
  • Folding is best done using a press brake or folding machine for precise bends.
• Welding:
  • TIG welding is the preferred method for stainless steel due to its clean, strong welds.
  • MIG and stick welding are also possible but require stainless-specific filler materials.

Care & Maintenance:

• Cleaning:
  • Can be cleaned using detergents, bleaches, and acidic antibacterial products.
  • For Grade 430 stainless, only use mild detergents, as harsh chemicals can cause corrosion.
• Corrosion Resistance:
  • Grade 430 is not suitable for outdoor use as it will eventually rust.
  • Grade 304 offers good corrosion resistance outdoors.
  • Grade 316 is the best choice for marine environments, as it withstands saltwater exposure.
• Tea Staining Prevention:
  • Outdoor stainless steel installations (e.g., handrails and exterior cladding) should be specified correctly to prevent “tea staining” (brown discolouration). This issue occurs when lower-grade stainless is used where 316 is required.

 

Zinc Sheet

Properties:

• Naturally Weather-Resistant: Zinc is highly corrosion-resistant, making it an excellent choice for roofing and architectural applications.
• Self-Healing Patina: Over time, zinc develops a protective patina, preventing further corrosion.
  • When new, zinc appears shiny, but over a few years, it transitions to a soft mid-grey.
• Soft & Easy to Shape: Zinc is highly malleable and one of the easiest metals to work with.
• Standard Specification: Zinc sheet at Metal Offcuts conforms to EN988, ensuring high quality and uniformity.

Common Applications:

• Kitchen Worktops & Splashbacks – Used for tables, countertops, kitchen islands, and bar tops.
• Decorative Wall Panels – Aged patina zinc sheets bonded to timber are often used as industrial décor accents.
• Roofing & Cladding – Found on high-spec buildings for its durability and aesthetic appeal. Pre-patinated zinc is available in various shades to expand design possibilities.
• Bespoke Furniture – Often used for desks, vanity units, cupboards, doors, and drawers, as well as inlays and accents.

Finishes Available:

• Natural Zinc – Starts bright and patinates over time.
• Patinated Zinc – Available in light grey, dark grey, and black patinas, as well as muted grey tones for a subtle industrial look.
• Pre-Weathered Zinc – Uniform monotone light grey finish for consistent aging.

Workability:

• Cutting & Drilling:
  • 0.8mm thickness is commonly used for DIY projects such as tabletops and countertops.
  • It can be bonded to a substrate and peened over with a mallet or pre-folded before affixing.
  • Press brakes and folding machines produce precise bends.
• Temperature Considerations:
  • Zinc is best worked at room temperature.
  • Below 7°C, tight bends may cause fractures—bending is best done above 10°C.
• Shaping & Soldering:
  • Zinc can be beaten into curved shapes and formed using shrinkers, stretchers, and roll formers.
  • Soldering is straightforward using tin/silver pre-fluxed solder. Ensure joints are well cleaned.
  • Preheat with hot air for better results, and use a 200W soldering iron for optimal performance.

Care & Maintenance:

• Patina Development:
  • Zinc forms a protective patina over time, giving it a unique aged look.
  • Chemical patinas (e.g., copper sulfate mixtures) can be used for custom finishes.
• Minimal Maintenance:
  • Outdoor zinc naturally develops a patina and requires no cleaning.
  • Indoor zinc can be lacquered or waxed to preserve its patina.
  • Cleaning with mild, soapy water is fine, but harsh cleaners should be avoided to prevent damage.

 

Corten Sheet

Properties:

• Weathering Steel: Corten steel is a high-strength, low-alloy steel designed to form a stable, rust-like appearance over time.
• Corrosion-Resistant Patina: Unlike standard steel, Corten develops a self-protecting oxidation layer, which prevents further rusting.
• High Strength & Durability: Corten is stronger than mild steel, offering excellent tensile strength and structural integrity.
• Distinctive Aesthetic: Characterized by its deep orange-brown patina, which evolves with exposure to the elements.

Common Applications:

• Architectural Features – Used in façades, cladding, signage, and wall panels for a bold, industrial aesthetic.
• Landscaping & Garden Design – Popular for planters, retaining walls, and edging.
• Sculptures & Public Art – Favored by artists and designers for its organic, weathered appearance.
• Structural Uses – Suitable for bridges, outdoor steelwork, and fencing, where weather resistance is crucial.

Finishes Available:

• Raw Corten Steel – Supplied in its unfinished state, allowing the patina to develop naturally over time.
• Pre-Weathered Corten – Some suppliers offer pre-patinated sheets for an instant aged look.

Workability:

• Cutting & Shaping:
  • Corten can be cut using a plasma cutter, laser, guillotine, or mechanical saw.
• Welding:
  • Requires special welding rods to maintain corrosion resistance.
  • TIG, MIG, or stick welding can be used, but Corten-specific filler rods should be chosen for longevity.
• Forming & Bending:
  • Corten can be bent like mild steel, but its higher tensile strength makes it slightly harder to form.

Care & Maintenance:

• Low Maintenance:
  • Once the patina forms, Corten requires little to no upkeep.
• Managing Runoff & Staining:
  • Initial rusting may stain nearby surfaces such as concrete or stone.
  • Water management should be considered in architectural applications.
• Sealing Options:
  • Clear sealants can be applied to reduce rust runoff while maintaining the weathered aesthetic.
• Interior Use:
  • For indoor applications, sealing with clear lacquer, beeswax, or Owatrol prevents rust dust transfer.

 

Pewter Sheet

Properties:

• Soft & Malleable: Pewter is a low-melting-point alloy (approx. 245°C) that is very soft and highly malleable.
• Non-Tarnishing: Unlike silver, pewter does not oxidize but develops a light patina over time.
• Lead-Free Alloy: Metal Offcuts pewter sheets are lead-free Pewter 92, conforming to EN611:
  • 92% Tin, 6% Antimony, 2% Copper – Ensuring durability and workability while remaining food-safe.

Common Applications:

• Decorative Metalwork – Used for plaques, frames, and artistic engravings.
• Jewellery & Crafting – Ideal for handcrafted jewellery, charms, and embossed designs.
• Engraved Signage – Perfect for personalized gifts and corporate branding.
• Tableware & Drinkware – Common in goblets, tankards, and plates due to its food-safe properties.
• Hospitality & Design – Spin-formed pewter is used for round table tops, bar tops, and food counters.

Finishes Available:

• Satin Pewter – Soft, brushed finish for subtle elegance.
• Bright Pewter – The natural condition of new pewter sheets.
• Polished Pewter – Reflective, but softer than polished silver.
• Antiqued Pewter – Darkened for a vintage or aged effect.

Workability:

• Cutting & Engraving:
  • Easily cut with hand tools, saws, or CNC engraving machines.
• Embossing & Stamping:
  • Soft enough for detailed relief work and intricate designs.
• Malleability:
  • Can be formed around corners and shaped with a mallet.
• Casting & Soldering:
  • Pewter is easy to cast and can be joined using low-temperature soldering methods.

Care & Maintenance:

• Hand Wash Only:
  • Avoid dishwashers, as heat can warp thin pewter sheets.
• Cleaning & Polishing:
  • Use mild, soapy water and a soft cloth for routine cleaning.
  • Specialized pewter polish can restore original shine.
• Avoid Harsh Chemicals:
  • Acids or abrasives can dull the surface.

 

Material Comparison Chart

Material	Corrosion Resistance	Workability	Common Uses
Aluminium	High	Easy	DIY, signage, splashbacks, buildings
Copper	Medium (Patinas)	Easy	Kitchens, furniture, crafting, interior design
Brass	Medium-High	Moderate	Decorative panels, engraving, interior design
Stainless Steel	Very High	Difficult	Kitchens, industrial use, automotive, buildings
Zinc	Medium (Patinas)	Easy	Roofing, worktops, furniture
Corten Steel	High (Patina Forms)	Moderate	Architecture, landscaping, sculptures
Pewter	Medium (Can Dull Over Time)	Very Easy	Jewellery, decorative items, engraving, interior design

Frequently Asked Questions (FAQ)

How do I choose the right metal for my project?

Consider the key properties you need, such as:

• Strength & Durability – For industrial or structural applications (stainless steel, Corten).
• Corrosion Resistance – If the metal will be exposed to moisture (aluminium, stainless steel, Corten).
• Ease of Fabrication – For easy cutting, bending, or engraving (aluminium, copper, brass, pewter).
• Aesthetic Appeal – For decorative features (brass, copper, zinc, pewter).
• Weight – Is weight a consideration? Aluminium v Steel
• Budget – Some metals, such as stainless steel and Corten, are more expensive than aluminium or zinc.

If you’re unsure, contact us for expert advice!

What are the weights of different metals?

A general rule of thumb for a square of sheet metal 1m x 1m x 1mm thick:

• Aluminium – 2.7 kg
• Copper – 8.9 kg
• Brass – 8.4 kg
• Stainless Steel – 7.9 kg
• Zinc – 7.2 kg
• Corten Steel – 8.0 kg
• Pewter – 7.3 kg

Do you offer custom-cut sizes?

✅ Yes! We provide free cutting services (for sheets bought through the shop) to ensure you get the exact dimensions needed for your project.

We specialise in supplying cut-to-size sheets working to your cutting lists, and we can quote you for:

• Straight cuts using a guillotine.
• Complex shapes laser cut (available for stainless steel, aluminium, brass, zinc, Corten and copper).

Do you offer fabrication services?

✅ Yes! We offer a full fabrication service, including:

• Cutting – Guillotine and laser cutting.
• Bending – Up to 3m length using press braking.
• Welding – TIG and MIG welding for stainless steel, aluminium, copper, and brass.
• Engraving – Rotary engraving, diamond drag engraving, and laser engraving.

Use our enquiry form for a custom fabrication request!

Do metals come with a protective film?

Most of our sheet metals include a peelable protective film on the face side to help prevent scratches during handling and transport.

✅ Protective film included:

• Aluminium (except checker and stucco finishes)
• Brass
• Stainless steel
• Copper

❌ No protective film (but sheets are handled carefully):

• Checker Plate Aluminium
• Stucco Aluminium
• Pewter
• Corten Steel

How do I prevent tarnishing or corrosion?

• Aluminium & Stainless Steel – Naturally corrosion-resistant; aluminium can be painted or anodised for added protection.
• Copper, Brass & Zinc – Develop natural patinas over time. To maintain brightness, use metal polish or apply a protective lacquer.
• Corten Steel – Forms a rust-like patina that protects against deeper corrosion. If left untreated indoors, sealing is recommended.

Can I paint or coat metal for a different finish?

✅ Yes! Many metals can be painted, anodised, lacquered, or chemically patinated for a custom look.

• Aluminium – Best painted with an etch primer and topcoat. There are special grades of aluminium for anodising.
• Copper, Brass & Zinc – Can be lacquered, waxed, or chemically aged.
• Stainless Steel – Not commonly painted. The finish is itself.
• Corten Steel – Can be painted or just left to rust outdoors

Need a specific finish? Contact us for expert advice!

Need More Help? Contact Us!

If you’re unsure which metal to choose or need custom fabrication services, our team is happy to assist!

Get in touch today for expert guidance and custom-cutting services!