We recently completed a project manufacturing a set of custom perforated metal panels that are both structurally sound and aesthetically pleasing. Careful assistance was provided during the custom design process, taking a concept into a manufacturable panel. Services included custom metal perforation and turret punching, sheet metal bending and surface finishing via in-house deburring and powder coating. Each panel is now ready to install and has an even perforation pattern, reinforced side edges, and a durable white powder coat finish for extended usage.
Custom Perforated Metal Panels are made on site by cutting metal panels with high-quality sheet metal turret punching machinery, then powder-coated in-house.
Design Phase and Planning of Perforations
The beginning of this project involved taking a design concept and transforming it into a manufacturable metal panel with a specific perforation pattern. We worked with the client to refine the design so that the spacing of the perforations, size of the holes, and overall dimensions of the panel could be fabricated to meet the structural needs of the application. Determining how many perforations per square inch will be in your panel is important, as this will affect the structural integrity, ability to attach to the surrounding structure, airflow, and overall visibility of the panel.
Through the coordination of the customer’s design intent and the capabilities of our manufacturing processes, we were able to create panels that met both the functional and aesthetic expectations of the customers’ architectural goals.
Creating Perforations Using Turret Punching
Using our 30T Finn-Power turret punch machine, we were able to create the desired perforation pattern on each sheet. The turret punching process creates multiple perforations of various sizes in a specific and repeatable pattern across each sheet. Being able to create holes of different sizes in each piece allowed for a complex design to be achieved while maintaining the structural integrity of the sheet metal.
Each panel was produced to professional standards and the client’s exact specifications for easy installation.
Using Press Braking to Allow for Easy Assembly or Mounting
Once the panels were perforated, we moved them to our Amada CNC-controlled benders to bend and create the side flanges as per the specifications. The bends create structural support for the panel by adding stiffness and helping to prevent it from warping or sagging.
The formed flanges also provided mounting areas on each panel, providing a secure way to attach the panels and to position them properly during the installation process. This helped to ensure the panels performed as expected and maintained their shape over time.
De-Burring and Surfacing to Prepare the Panel for Powder Coating
During the punching operation, there were small burrs left along the edge of each hole and along the perimeter of the panel. Removing these is necessary to allow the panels to be handled safely and to ensure good adhesion of the coating to the metal, as well as furthering the aesthetic appeal.
To remove these burrs and to prepare the panels for powder coating, we used our specialised Q-Finn automatic Surfacing machine to deburr, etch and clean up the panels.
Applying the Powder Coat Finish
All panels were powder-coated in-house using a zinc primer followed by a white topcoat. The zinc primer protects against corrosion by isolating the base metal from exposure to the elements, and the white topcoat provides a durable and uniform finish.
Powder coating provides a consistent coating thickness and good adhesion to the metal, creating a surface that is resistant to wear, corrosion, and environmental conditions while presenting a clean, professional appearance.
Fabricating Precision From Design to Finished Product
We enjoyed working with the client to develop their design ideas and to manufacture fully finished perforated metal sheets. With our ability to perform turret punching, forming, surface preparation, and powder coating in-house, we had complete control over the quality, accuracy, and delivery date of each panel.
Our experienced team can help you with custom perforated panels, precision sheet metal fabrication and other metal products from start to finish with reliable manufacturing and excellent results. Give us a call today!