How Safes Are Made: The Material and Manufacturing Process

Safes are among the best additions to any home, office or business premises. Most folks, despite being aware of how essential these accessories are to keeping their item safe, have little to no knowledge whatsoever, or how they are made or the materials used to manufacture them.

Therefore, this article will tackle the manufacturing process of safes, the materials used and essentially, the components that make up a safe. Let’s get to it!

What Types of Steel are Used for Safe

1. Carbon Steel

carbon steel
source: https://www.tekportal.net/carbon-steel/

Carbon steel is a caustic metal that has a dull, matte look. This one is divided into three subtypes: low, medium, and high carbon steel, with low carbon steel comprising about.30 percent, medium.60 percent, and a high 1.5 percent. The term originates from the fact that they only have a minimal quantity of other alloying substances in them. Cutlery, high-tension wires, vehicle components, and other similar products are routinely constructed from them due to their extraordinary durability.

2. Alloy Steel

This is a combination of various metals, including nickel, copper, and aluminum. These are preferred for various automobile components, pipelines, ship hulls, and mechanical applications since they are less expensive and more rust proof. The toughness of this one is determined by the concentration of the components it contains.

3. Tool Steel

Tool steel is noted for its toughness, thermal resilience, and corrosion resistance. The moniker derives from the fact that they’re regularly used in the production of metal tools like mallets. The main reason for tool steel’s exceptional thermal dissipation and durability is that it is made up of two constituents: cobalt, molybdenum, and tungsten.

4. Stainless Steel

Stainless steels are the most well-known form of steel on the market. This kind is gleaming and has a chromium content of 10 to 20%, which is the principal alloying element. This combination permits the steel to be abrasion-resistant and readily moulded into a variety of forms. Owing to its simplicity of manipulation, versatility, and sturdiness, stainless steel may be commonly used in medical gear, domestic cutlery, and even as exterior cladding for commercialized structures such as metal gun cabinets.

Gauge for Steel Thickness

The standard thickness of sheet metal for a certain substance is indicated by a sheet metal gauge (sometimes written “gauge”). The material thickness reduces as the gauge number rises.

Steel sheet metal thickness gauges are built on a mass per square foot of 18.96 Kilograms per inch of the thickness of 18.96 kilograms per inch of thickness of 18.96 Kilos per inch of the thickness of 18.96 Kilos per inch of thickness The Producers’ Standardized Gage for Sheet Steel(known reference). Other substances, such as aluminium and brass, will have varying thicknesses. As a result, a 10 gauge steel sheet with a 0.1345-inch thickness will take 18.96*0.1345 = 2.55012 kilogram per square foot. 

Safe Manufacturing Process


Cutting techniques function by fracturing the material being worked on. The section of the bone that is fragmented away is usually in little fragments called chips. Sawing, shaping (or planing), broaching, drilling, grinding, turning, and milling are all frequently adopted techniques. Despite the fact that the cutting machines, equipment, and methods may appear to be highly diverse, the essential mechanism for creating the fracture may be described using a simple model termed orthogonal cutting.

The goal is to remove any surplus material and produce the final product of the safe. This cutting is normally done in numerous phases, with the item being held in a fixture at every step and the tool accessing the revealed section to the machine in that section.


Bending is a metal forming technique that involves applying a force to a sheet of metal, forcing it to bend at an angle and produce the required shape. A bending operation induces deformation along one axis, however, a complicated component can be created by combining multiple distinct processes. Bent pieces can be as little as a bracket or as huge as a massive enclosure or chassis, which can be up to 20 feet long. Several parameters may be used to describe a bend, as indicated in the diagram below.

The process of bending causes the sheet metal to be both tensioned and compressed. The exterior of the sheet will feel strained and stretch to a higher length, while the interior will be compressed and shorter. The neutral axis is the interior sheet metal borderline where no tension or compression forces exist. As a consequence, the axis’ length stays unchanged. Two factors, bend tolerance and bend subtraction, can be used to link variations in lengths of the outer and interior surfaces to the initial flat length.


Welding is a method of connecting two materials jointly without the need for a separate binder. Welding, in contrast to brazing and soldering, which require a lower melting point binder, unites the two workpieces directly. This distinction is critical to comprehending welding and why it is favoured for the long-lasting, robust construction of a metal safe box.

Welding helps in assembling the safe’s design into a complete product.

Powder Coating

Powder Coating
source: Safewell

Powder coating is a sort of dry, unrestricted coating. Unlike traditional liquid paint, which is sprayed electrostatically and then treated under heat or with UV light, powder coating is often administered electrostatically and then treated under heat or with ultraviolet light. It’s possible that the powder is made of a thermoplastic or thermoset polymer. It’s frequently used to provide a harder finish than regular paint.

The most popular method to utilize powder coating on metal items is to use an electrostatic gun. The powder is given a negative charge by the cannon and then sprayed towards the exposed item by mechanical or pressurized air spraying, before being driven toward the workpiece by the high electrostatic charge. Electromagnetic coating spray snoot comes in a variety of forms and dimensions. The type of nozzle to use will be determined by the form of the safe to be painted as well as the paint consistency. The powder melts into a homogeneous film on the heated item, which is then cooled to produce a hard coating on the metal gun safe

The Components of Safe

1. Box Body

The outside surface of the safe is the body. The most common material for this layer is thick steel or similar strong and heavy metal. The contents within the safe are best protected by the safe’s body. It also makes the safe heavier, making it harder to pick up and transport. Bullets, fire, and even explosive devices have little effect on most safe bodies. Current producers may ensure the protection of key items for up to four hours in a 2,000 degree Fahrenheit direct flame by choosing alloys with poor heat transfer.

2. Door

The majority of safe doors have the same thickness as the rest of the structure. They work with interior hinges on swinging doors. Some doors are hinged on the side and swing open. Some, like a treasure box, open from above. These doors, like the body, are often made of metal and add to the safe’s mass. Absolute fireproof security is provided by doors that have a snug fit and an airtight seal, as well as limited heat transfer.

3. Lock

digital safe lock 1
source: Safewell

Locking mechanisms come in a variety of shapes and sizes, but all real safes feature at least one. The lock consists of single or numerous metal rods that prohibit the door from unlocking. By pushing these metal rods into the safe’s body, locks hinder the door from unlocking. The most frequent is a spinning tumbler with a sequence that must be disengaged with the right clockwise and counterclockwise revolutions. Sophisticated features such as digital combinations, fingerprint scanning, and retinal scanning are also used to operate locks. Despite the intricacy of lock types, most safes’ locking mechanisms are the weakest point of access.

4. Bolts

It is a locking device that secures the safe’s door and prevents it from being forced open.


Safecracking is the practice of forcing a safe open. Opening a safe is a skill that necessitates a high level of technical understanding as well as the proper tools. When essential components break down for whatever reason, technicians are summoned to force open safes.

There are several ways for breaking into safes, some of which are approved and utilized by professional specialists and others that are favoured by criminals. Professional technicians are supposed to force the safe open in a secure way that does not expose the safe thereafter.

The procedure of breaking into a high-security safe is incredibly difficult. Drills, hammers, levers, thermic lances, torches, and explosives are among the instruments of the trade. Drilling is a particularly difficult process.

Law enforcement and government entities are the only ones who can take courses and get hands-on experience.

How to Keep a Safe Secure from Intruders

In Opposition to a Drill

Behind the door, a manganese sheet is put. We will not give you any instructions on how to open a safe. Of course, this isn’t a how-to manual for thieves to carry out their illegal business, even though many locksmiths are required to know all of this in order to repair safes and assist clients. All of this information is useful not just for specialists in their fields, but also for consumers who want to know how things function. It assists in making the best financial and security decisions. In general, a well-informed individual is more powerful. It may also assist in determining whether to seek expert assistance in order to fully comprehend the quotation or invoice. Also, put your faith in your neighbourhood locksmith.


Evidently, every reputable safe manufacturers like us, Safewell, goes through a defined procedure of ensuring that you get the highest quality of safes. Therefore, reach out to us with any specifications and inquiries and our experts will be happy to meet them all.

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