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Design, Production, and Typical Uses of Perforated Metal

Perforated metal is a product of numerous mechanical processes. Its production is simple, yet complex, and its uses are without limits. Metal was first perforated or punched back in the 1870's in Carbondale, Pennsylvania. Eli Hendrick an inventor and entrepreneur, conceived the idea to punch multiple holes simultaneously in the raw materials to refine the process of drilling holes individually which was both time consuming and costly. This idea revolutionized the production of perforated metal products.

The raw materials used in the production of perforated metal products are widely varied in width, gauge (thickness), and composition. Some examples of raw materials regularly perforated are mild or carbon steel, aluminum, galvanized, copper, stainless steel (in a variety of grades), as well as numerous alloys. The perforating process actually varies with respect to the raw material being processed in multiple ways including the lubricating oil used for cooling the perforating punches and the speed at which the holes can be punched.

The raw material is fed mechanically or using electric servo motor controls through the mouth of the perforating press as the head of the press repeatedly oscillates up and down. Today's perforating presses can achieve punching speeds of up to 700 strokes per minute. The punches strike the material causing it to break through the metal at the point of impact in the desired size and shape. The specific shape and size of the holes are determined by the perforating tool. One strike of the punches produces holes across the material perpendicular to its movement through the press. One revolution of the perforating press can produce single or multiple rows of holes depending on many variables including the perforating tool and the customer specifications. The size, shape, and the pattern of holes is specific to each individual application. The feeding of the raw material is sychronized with the up and down motion of the perforating ram within the press to produce repetitive patterns.

The resulting perforated material can then be subjected to additional processes depending on its intended use. The metal can be sheared to length or it can be wrapped into a coil. It can be cleaned and washed, deburred, painted, and formed or bent into various shapes. As a result of numerous fabrication techniques including (but not limited to) welding, the perforated metal can become many different stand-alone products or parts of end-user products.

Perforated metals are found virtually everywhere from automobile parts to small appliances and from rock quarries to computers. Many design factors contribute to the specific application. A wide range of hole sizes and shapes of course are available. The holes can be arranged into staggered or straight line patterns. The type and thickness of the metallic raw materials are also critical to the intended use. Small holes for instance are ideal for filters and filtration of fine particles in both air and liquid. A complete product line can be based on filtration itself. Moderate sized holes have found a place in decorative or architectural products including building facades and lighting diffusers. Larger diameter holes are used on mining and aggregate application usually punched in a heavy gauge material.

It seems once you've taken an interest in perforated metal products you can find them almost everywhere in one form or another. Perforation is visible in industrial facilities, the exterior design of buildings, decorative lighting over our heads, and in everyday appliances we use at home.

About the Author

Chet is a 16+ year employee of Hendrick Manufacturing Company, a leader in the perforated metal industry. Hendrick Manufacturing has operated continuously in Carbondale, Pennsylvania since 1876.

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