With so many patterns and metal choices, how can you be sure that you are choosing the right perforated metal profile for your project?
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In this easy reference guide, we will take you through all the key considerations, so that your finished perforated metal profile meets all project requirements, from visual aesthetics and light flow to privacy, performance and durability.
Our expert manufacturing and design team are always on hand to advise on pattern or metal choice that suits your needs, including creating a custom perforated metal design.
The most important consideration is what you need the perforated metal profile to achieve once it is installed, as this influences everything about your panel design, including the hole shape, pitch, open area percentage, panel thickness, base metal, and finish.
For instance, a profile selected for only aesthetic reasons can be made with a much wider range of patterns and metals than a profile that will be load-bearing or installed in a marine environment.
Many perforated metal profiles that we manufacture need to be multi-taskers and serve several functions at once. Such as panels for facades and balcony screens, which often require visual impact, privacy, light and airflow, acoustic absorption, strength, and durability, all in one design.
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Whilst this sounds complex, it is easy for us to achieve. Most elements of our pattern designs can be adapted to meet exact project requirements. We also have a customisable architectural collection ideal for multi-panel, high-end project needs, and our unique PixelPerf bespoke perforation service, that produces your own design in metal.
Let&#;s look at pattern basics and explain what some of the terms mean when you are browsing our range of perforated metal profiles.
At Arrow Metal, all our profile PDFs include the following information:
The basic hole style &#; such as round, square, slot, or hexagon. Which should you choose? Round is the most widely used hole shape as it is versatile for all kinds of designs, particularly when replicating images and graphics in perforated metal. Round is also the strongest hole style, offering high strength even for open, airy patterns.
Hexagonal holes are ideal when you need a high open area percentage (so more light and airflow), whilst slotted holes are great for visibility.
For example, take a look at the 3mm aluminium panels that we manufactured for Sydney Motorsport Park, in pattern P378A with a 60% open area. The goal of this project was a metal barrier for spectators, without obstructing visibility. By using horizontal slots, the racetrack is easily seen, whilst still separating and protecting racegoers. If on the other hand, you want to limit visibility horizontally, the slots can be punched vertically instead.
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These are the metal types that we can perforate in that pattern. When deciding which metal to choose, think about the installation location. Inside or outside? Marine or inland environment?
The conditions your panels will need to withstand day after day will dictate your metal choice. Metals like stainless steel and aluminium for example are ideal for coastal and marine environments because of their corrosion resistance.
However, other metals such as brass &#; valued for its decorative appeal and aesthetics with other materials &#; can also be used outside. But remember that brass will naturally oxidise over time, resulting in a weathered look.
You can compare different metals in our quick-reference table below (or click here to see it), that covers key factors such as location suitability, weight, and more, with useful comments from our expert team to help you narrow your choices.
Hole sizes, in combination with open area percentage, affect the visibility, light, acoustics, and airflow properties of your panels. Remember that in most designs, we can punch the holes larger or smaller, to meet your specifications.
Whether the holes are in a staggered format (diagonal) or straight when perforated into metal. The pitch determines the aesthetics of your panel and can also influence panel strength. We can customise the pitch to suit your needs, and punch holes in any direction for visual impact.
Shown as a percentage, the open area is how much of the panel is made up of holes, and how much is solid metal. The higher the open area percentage, the more light and airflow; the lower the open area percentage, the better for privacy and shade &#; so striking the right balance is vital.
So now you know what to consider, and the many different factors that affect profile suitability, we will help you to place the right order.
We have extensive expertise in metal perforation and can advise which patterns, metals, open area percentages, panel thickness, and hole sizes match your project requirements, saving you time and the worry of making costly metal mistakes.
Simply contact us on (02) or for a no-obligation project discussion.
You can also download our brochure here to learn more about our perforated metal capabilities, pattern range, custom PixelPerf perforation service, and finish choices including colours, effects, and durable coatings.
As perforated metal manufacturers with almost 30 years in the industry, our panels are used for major projects across Australia, trusted by household brands, shopping complexes, education, transport, and leisure sectors, and more.
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Browse or download our Perforated Metal Catalogue , Brass Woven Wire Mesh Catalogue or Project Look Book for more perforated metal inspiration.
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The smallest hole size that can be perforated in metal is typically equal to the material thickness. The physical and chemical properties of certain materials like brass, aluminum and steel may allow smaller hole sizes than the material thickness to be perforated.
The Perforating Industry has defined a number of standard hole patterns, they can be found here: Standard patterns
Ferguson Perforating&#;s standard tooling allows over a thousand different perforation patterns to be produced. Often we can come very close to what you are looking for by programming the perforating press accordingly. We can also manufacture specific special perforation tooling to meet your needs if so desired. This is very economical when you have a larger need for a certain perf pattern that we do not already have available.
We can perforate stainless foil down to a thickness of 0.008&#;.
Numerous metals and plastics can be perforated. Commonly perforated materials can be found under Material Info.
The open area of a perforated sheet is dependent on the hole pattern and can be calculated using the open area formulas.
The main factors influencing the perforated part cost are: Material cost, Perforated pattern&#;s level of difficulty (Hole size versus Material thickness, Side & End Margins, Perforation end patterns), Tolerances, and the Quantity ordered. More on this subject can be found under Design Considerations.
The following insights are offered on each of the factors that affect the quality, cost, and delivery of perforated product. In order to manufacture a high quality, low cost product that is deliverable within acceptable lead times, it is important to acknowledge these factors when designing and/or specifying perforated material. They are:
It is important to utilize the right material that meets the stresses and demands of the application. At Ferguson Perforating, we will help in choosing one that is commonly perforated, and is likely to be more readily available. We are always willing to specify material origin (i.e. Domestic, NAFTA, or other) and/or CERTS needed when requesting a quote. If this is important, please let us know at time of quoting. Failure to do so at the RFQ stage may result in Ferguson Perforating having to re-quote the requirement due to increased lead times and/or price.
Varying thicknesses can be perforated using our perforating technology. Our perforating presses are designed to handle materials that range between .004&#; to .500&#; thick. Feel free to call 1-800-341- for a quote based on material type and thickness.
A seemingly endless range of hole sizes can be perforated. The ability to perforate them is dependent on the thickness of the material. Usually a greater than 1 to 1 ratio should be maintained (i.e. 1/8&#; holes in 1/16&#; thick material). Punches may break resulting in either imperfect or missing holes in the material if this tolerance is not held to standard. There are exceptions to this rule based on varying qualities in material, etc. For this reason, where applications require the 1 to 1 ratio to be either pushed or exceeded, it is best to discuss with a Customer Service Representative the tolerance allowance for imperfect or missing holes and the cost associated with meeting that tolerance.
At Ferguson Perforating we will help you to choose the best hole shape and configuration that can be produced with existing tooling so you can minimize costs and enable faster delivery.
While choosing a perforation pattern that offers the required percent open area is of great importance, perf patterns with extreme open area proportions (i.e. 60% and higher) increase material distortion and can adversely affect quality and/or increase costs resulting from efforts to minimize the distortion. This is especially true when the perforated area is surrounded with margins on all four sides.
Margins can increase the difficulty in getting material within a desired flatness tolerance and can cause camber (bow). This is especially true when:
To minimize the amount of work and the associated cost required to get the material flat and without camber, either reduce or change one or more of these factors. If unable to do so, consideration may have to be given to allow for less stringent tolerances.
&#; Unfinished and Finished
Unfinished End Patterns are standard in the perforating industry. Finished ends can also be produced. In many cases, perforating finished ends requires special production techniques and for this reason, finished ends may increase costs. To find out if a desired pattern can be produced with finished ends, contact one of our Customer Service Representatives. Unless otherwise specified, unfinished ends are quoted and produced.
Blank areas and/or locator holes can be made in any pattern. The ability to do this is dependent on the versatility of the tool (i.e. center spacing). If you can provide us with a drawing of the part a member of our Sales Representative staff will advise you if we have a tool available to accomplish this, or if we would need to make a new tool. The difference in this decision process would be reflected in the cost.
At Ferguson Perforating, we aim to meet your specific tolerance standards if at all possible. We currently meet some of the strictest of standards in the world with some of the highly sensitive products that we perforate.
While measures are taken to keep surface blemishes to a minimum, imperfections resulting from perforating, roll leveling, and shearing do occur and are therefore considered standard and acceptable. If material surface finish is critical, then it should be indicated on the request for quote so additional precautions (i.e. use of vinyl coated material, paper interleaving, etc.) are planned for and the cost is adjusted to consider the additional detail.
At Ferguson Perforating, we regularly supply degreased, fabricated pieces. Please request these secondary operations so we know to quote as they will affect pricing. Secondary operations add value to your perforated product, while they increase the cost per part; by having Ferguson Perforating perform these operations it is easier and often costs less than if done by the customer.
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