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The best tool for cutting metal ducts depends on the duct's shape and thickness. For round ducts, a duct cutter provides accurate, clean cuts. Reciprocating saws equipped with metal-cutting blades are versatile and suitable for both round and rectangular ducts. They offer speed and precision, especially for thicker metal. 

Tin snips are handy for intricate cuts or smaller ducts. However, an angle grinder with a metal-cutting wheel is powerful and efficient for large or thick metal ducts. 

Metal casting involves creating a prototype and a mold into which metal is poured and allowed to cool and set up. Pieces are cast in molds, making the reproduction of many identical pieces more efficient for larger quantities. Metal fabrication involves creating pieces and welding them together into a larger project, involving more skilled manual labor than metal casting. Fabrication can be more cost-effective in smaller runs but can become less efficient for producing mass quantities of identical pieces.

Welding is the process of using extreme heat—and, sometimes, pressure—to attach two pieces of metal. In contrast, metal fabrication is a more involved process that can include welding, sheet metal work, bending, and other forms of metal manipulation. Metal fabrication is a large-scale project that may or may not involve welding, while welding is more often a step in larger fabrication projects.

You should not do your own welding unless you have the proper training and experience. Most home electrical systems can only handle MIG welding, which creates weaker bonds than TIG welding and won’t work on certain metals or metal thicknesses. Both welding forms usually require the use of shielding gas, which can be dangerous to store at home. Additionally, welding machines create temperatures of over 3,000 degrees, and the sparks can blind you if you don’t have the proper equipment. As such, it’s usually better to hire a professional welder for your welding projects.