Precision Laser Welded Cylinders: Meeting the Demand for Large Diameter Light Gauge Tubing

Meeting the Market Gap in Large Diameter Light Gauge Tubing

In many industries, engineers and buyers face the same recurring challenge: finding large diameter light gauge tubing that meets both performance and cost requirements. Traditional tubing suppliers often focus on smaller diameters or heavier wall thicknesses, leaving manufacturers with limited options. For those who require tubing in the 6-inch to 16-inch range with thicknesses from 20ga (0.036”) to 14ga (0.075”), the search can be frustrating.

Church Metal addresses this gap directly by offering precision-rolled and laser welded cylinders in both stainless steel and low carbon steel. With diameters, gauges, and materials tailored to customer needs, we make it possible to source tubing that was once difficult—or impossible—to procure.

Materials That Match Your Application

Not all tubing applications are the same, which is why we provide cylinders in several material options:

• 304 Stainless Steel – corrosion resistance and durability for demanding environments.

• 409 Stainless Steel – ideal for automotive applications where heat and oxidation resistance are key.

• 439 Stainless Steel – ferritic stainless steel with excellent formability and weldability.

• Low Carbon Steel – cost-effective choice where strength is critical but corrosion resistance is not the primary factor.

This material variety ensures that customers in industries such as automotive, HVAC, industrial equipment, and fabrication shops can find the right fit for their specific needs.

The Process: From Laser Cut Blank to Finished Cylinder

One of the most significant advantages of working with Church Metal is our integrated process. Each cylinder begins with a laser cut blank, which serves as the foundation for precision forming. Here’s why this matters:

1. Accuracy in Features – Holes, slots, and cutouts are added to the flat blank before rolling. This ensures uniformity once the tube is formed.

2. Consistent Rolling – Our urethane rolling machines deliver smooth, repeatable results that maintain strict dimensional tolerances.

3. Precision Welding – Laser welding minimizes the heat affected zone, resulting in cleaner welds, less distortion, and reduced need for secondary finishing.

The outcome is tubing that is not only dimensionally consistent but also ready to perform in downstream forming and fabrication processes.

Why Laser Welding Outperforms TIG Welding

Traditional TIG welding has long been the standard for tubing, but it comes with drawbacks such as wider heat affected zones, distortion, and additional finishing requirements. In contrast, laser welding offers several performance benefits:

• Reduced Heat Affected Zone (HAZ): Maintains material integrity and minimizes warping.

• No Need for Planishing or Grinding: Saves time and labor costs.

• Improved Formability: Our tubes consistently perform better in lateral bending applications compared to TIG welded tubing.

• Cleaner Welds: Creates a finished look without additional surface work.

For customers, this means shorter lead times, lower fabrication costs, and stronger, more reliable tubing.

Flexible Supply Options for Customers

We understand that every customer’s needs are different. Some want raw materials for in-house fabrication, while others prefer value-added solutions. Church Metal supports both approaches:

• Raw Welded Tubes – Supplied as-is for customers who have the capacity to fabricate further in their own facilities.

• Value-Added Processing – We provide press forming, spin forming, or hybrid forming services to create parts with concentric features and tight tolerances.

By combining multiple forming processes, we ensure close alignment between pre-cut holes and features and the newly formed dimensions. This saves our customers significant time in their manufacturing workflow.

Real-World Applications

The versatility of large diameter, light gauge cylinders makes them a critical component across a wide range of industries. Applications include:

• Automotive exhaust systems requiring durable stainless tubing.

• HVAC ducting where large diameter but thin-walled tubes are preferred.

• Industrial equipment housings that demand concentric features and custom cutouts.

• Agricultural machinery where strength and formability are essential.

Each of these sectors benefits from the precision and repeatability that laser welded tubing offers.

The Church Metal Commitment

At Church Metal, we don’t just deliver tubing—we deliver solutions. By investing in laser cutting, rolling, and welding technology, we help our customers overcome design and sourcing challenges. Our goal is to provide tubing that:

• Meets tight tolerances.

• Performs better in forming and bending.

• Offers consistent quality, order after order.

• Reduces customer lead times and fabrication costs.

This commitment has made us a trusted partner for companies that value precision, reliability, and long-term performance.

Finding large diameter light gauge tubing doesn’t need to be an obstacle. With Church Metal’s laser welded cylinders, manufacturers gain access to a product that is engineered for accuracy, durability, and performance. Whether you need raw welded tubes or fully processed, value-added parts, our team is ready to help.

If you’re looking for a reliable solution for 6-inch to 16-inch tubing in stainless or low carbon steel, contact Church Metal today.

Please contact us with questions. We do invite you to engage with us on social media (just not for immediate needs). Best to call, email or visit our site for the best response.

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