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Design

To provide the most effective perforated metal services, manufacturers consider a number of different factors. First, they think about what perforated metal pattern(s) might be best for your application. For example, if designing for an audio application, manufacturers will consider sound transparency. If you’re seeking high sound transparency, your perforated metal provider will design a series of perforations with a large open area. Likewise, if you seek low sound transparency, they’ll design perforations will a smaller open area. Other things they will take into consideration when designing and/or customizing perforated metal products are: space restrictions, safety standards and regulations, industry standards and time constraints.

Machinery Used

Wide Punching Press

Wide punching presses offer quick and inexpensive perforation. They feature a die and one or more punch rows that strike the metal plate as it moves through the machine. With each strike, it punches the entire width of the plate. Manufacturers can modify die and punch row patterns in order to create custom perforated metal products. Because the machine works so quickly, it is easy to find stress faults in the perforated part. To rectify this, metal perforators often use a leveler. This removes stress errors by flattening the plates. The main drawback of this perforation method is that is has a high tooling cost.

Sectional XY Axis Punching Press

To perforate using the XY press, sheet metal is secured to the machine and slowly moved around underneath one to several stationary single-shaped punching rams, which create a detailed perforated pattern on the metal as it moves in the direction of the hole design. This process is long, but patience rewards the metal worker with complex, precise, decorative perforated sheets and perforated metal panels. Though both manual and CNC punching methods have their merits, CNC punching tends to be preferred due to lower labor costs, higher production speeds and greater process repeatability. In addition, using CNC equipment, it’s easy to create custom programming.

Automatic Nibbling Machine

Automatic nibbling machines are quite similar to sectional presses, in that they work on just one section of plate at a time. Unlike sectional presses, though, their production, including perforation tool changes, is automated. They create perforations by nibbling contours. Automatic nibbling machines offer affordable perforating and good outer plate finishing. Like all perforating equipment, they can create custom features related to: strength-to-weight ratio, open area, hole diameter (measured in mm) and hole size (measured in mm).