How is Perforated-Decorative Panel Made?

Perforated Decorative panel is a form of sheet metal, which are being stamped or punched with an industrial machine to create patterns containing holes. These panels are also known as perforated plates, perforated sheets, or perforated screens and are typically made from aluminum composite, stainless steel, pre-painted galvanized steel, copper, zinc, etc. Perforated panels were first produced about 150 years ago, and they were meant to be utilized as a coal filter for the mining industry. Unfortunately, the perforation process was inefficient and faced failure. The laborers were forced to manually punch the individual holes into the metal sheet. However, nowadays, the process has extremely improved through the use of machinery which utilizes special punching needles that are arranged in specific patterns.

Perforated-Decorative panels play important role in modern architecture and interior decorations along with the other functional materials such as ACP, Wood sidings, Aluminum sidings, longboard sidings, etc. These panels are perfect for developing creative designs and eco-conscious, along the performance balancing with their visual appeal. Due to their sustainability and functionality, many exterior designers choose to utilize these products for modern constructions and use them for renovation and remodeling applications and projects. Decorative panels are available in a variety of color finishes which give the designers the opportunity of having limitless ideas of creating aesthetic appearance for residential and commercial buildings.

Perforated and decorative panels are produced and manufactured not only for aesthetic purposes but also to provide sound insulation, safety, thermal requirements, and light balance for the building. The production procedure of these materials gives them a combination of strong, functional, and precise characteristics. In addition, these products are considered as cost-effective materials for improving the interior and exterior of a facility with an atmosphere of space and light like aluminum plates and cassette panels, which are also very popular products in the building industry. Before choosing and utilizing these products, it is recommended to have project consultation with experts and professional contractors.

Perforated Decorative Panel Production Procedure

Perforated-Decorative panel’s production procedure usually starts with a coil of sheet metal in the required gauge. Sheet metal is typically a flat and thin material, which can be bent or cut into a variety of shapes and patterns. In some countries, the thickness of the material is defined and specified in gauges. The bigger gauge number means the metal is thinner. However, in some other countries, the sheet metal thickness is measured in millimeters.

Manufacturing modern perforated-decorative panels are relying on a few fundamental methods. Each method and procedure have its unique purposes, values, and advantages. The three main developing and manufacturing types of these products are Rotary Pinned Perforation, Punch Press, and Laser Perforation. Followings are the introductions to each method utilized in the industry.

Rotary Pinned Perforation

This process is one of the most popular and efficient methods of perforating sheet metals with high-quality standards. This process starts with large cylinders that are equipped with pointed, sharp needles along the outside. Then, sheet metal is being moved underneath the structure of the machine. While the machine rotates the sharp needles, cylinders continuously punch the sheet that passes below and create holes. In some cases, pointed needles require to be heated in order to melt the material on the inside of the punched holes. This process is done to fortify the rings of the perforation and increase the load-resistance and strength. The cylinders used in the machine can rotate at a considerably fast pace. Thus, Rotary Pinned Perforation can be the optimal method for punching a large number of identical holes at a quick rate.

Punch Press

A Punching press is a machine or device, which is used for manufacturing the majority of perforated panels. This machine features sharp tools which can be customized to demanding hole shapes and size. There are different types of punching presses.

One of the punching press machines used in the industry is called Wide Punch Press which features long rows of rams. In this method, the metal panel is being passed through the machine and the rams descend upon the panel to strike and perforate entire rows of holes only in one motion. Thus, they can improve the speed of perforation.

Another common punching press system is called the XY Axis machine. Unlike the wide punch system, this machine does not have long rows of perforation tools. Rather, it features either a single die or a limited clump of punching rams. In this method, the punching ram or die are moved across the immobilized panel section by section. This system is perfect for perforated panels that require complex design and non-repetitive patterns.

With either punch press method, a specific amount of panel along the length of the product will be held as non-perforated. This is for creating margins or solid blank areas around the edges of the product.

Laser Perforation

This system is considered the most focused method for perforating metal sheets. In this process, highly accurate beams start to produce holes by burning the surface of the sheet metal beneath them. This method is an extremely precise and versatile system for developing perforated panels. However, it can be time-consuming and costly when it comes to producing materials with large volumes.

Last Note

Utilizing the exact method for making perforated panels may vary depending on the pattern, panel size, time restraints, and other details. However, these manufacturing machines and technologies enable Perforated Panel production that is effective and dynamic.