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The following factors affect the selection of the type of screw to join sheet metal parts.
Sheet Metal Material
Experts recommend self-tapping fasteners for hard materials ( CRCA, SS), whereas machine screws are the best choice for softer materials such as Aluminum.
Sheet Thickness
Self tapping screws require larger sheet thickness to engage the recommended number of threads.
Assembly Approach
Machined screws have an application for multiple assembly and disassembly of the product, whereas experts recommend self-tapping for one-time product assembly.
Cost Constraints
Machine screws solution is costlier than self tapping screws.
Structural Requirements
Machine screws provide high clamping force compared to self tapping screws.
ID students, take note: Eventually you may want to present a project in metal. Depending on the object you design, it may be easier to fabricate the object in wood, then paint it to look like metal. Alternatively, you could skin a wooden object in sheet metal, which raises the problem of fasteners--do you want to see exposed screw heads? You could use adhesive, but you've got to be pretty bang-on, and it might be tough to undo an error.
I'm a new fan of designer/builder Matt Jackson's YouTube channel, as he's got tons of useful fabrication tips on it. His latest is how to attach sheet metal to wood, using this interesting "reverse rivet" method:
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I'm digging the look of the rivets and the simplicity of the method!
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