Custom Punch vs Stock Material
Our custom perforating is available when our clients requirements are different from our stock inventory sheets. Some custom requirements include:
- Alloy material
- Sheet dimensions (width or length)
- Hole size, pattern and percent (%) open area
- Areas not perforated around or through the sheet (borders and margins)
- Pattern orientation or direction
- Flanges for hammer mill screens
- Secondary services like aluminizing, powder coating, degreaseing, notching, mounting holes or bending
The customization is endless as the options and variations can be combined to make a custom perforated sheet. Below you will find a comparison of stock inventory and custom perforated option.
|Width:||36" or 48"||60", 72", coil|
|Length:||96” or 120”|
|Thickness:||24 to 1/4" plate||3/8" plate|
|Open Area:||23, 36, 40, 50, 58%||13%|
|Side:||1/8" to 3/8"||must be specific dimension|
|End:||no margins||must be specific dimension|
|Type:||finished and unfinished||finished|
|Material:||Steel, T304, Aluminum, etc.||A1008, Type 304|
Custom Punching vs Metal Stamping
Metal stamping and metal punching are two common methods of creating custom perforated parts. Metal punching uses a tool called a punch press and a specially designed tool and die set. Metal punch tools are typically made from hardened steel or tungsten carbide.
In a punch press, the workpiece is moved into place between the tool and the die. The tool is then forced downward into the die, creating a hole in the desired shape. The process is simple, fast and cost-effective, making it an excellent way to produce perforated sheet metal to your exact specifications.
Metal stamping is a more comprehensive process. Whereas metal punching is used to create perforations in an existing component, stamping uses more complex tool and die sets to create a finished part in one step. The benefits of this include faster turnaround times and the ability to quickly and economically mass produce components. The drawbacks include higher tool and die development costs.
Metal stamping is often not cost-effective for shorter runs. Punching is a more flexible process and doesn’t require an economy of scale. Both can be automated using CNC technology to achieve results with high dimensional tolerances and overall accuracy.
Our Fully Equipped Custom Fabrication Shop Is Ready to Assist You
As part of our ongoing quest to provide the best solution for every customer, we have a state-of-the-art, in-house fabrication department that contains the most advanced hole punching equipment on the market. This enables us to offer a wide assortment of premium perforated metal custom punching services, including:
- Hole size: If our standard round, slotted or square hole sizes aren’t quite right for your project, just let us know! We can alter the size of the hole to make it larger or smaller as needed.
- Hole pattern and pattern orientation: Typical perforation patterns include variations of straight-line and staggered. However, we can alter these patterns upon request. We can also change the pattern orientation and direction.
- Open area percentage: The amount of open area on a screen, vent or other product will significantly affect factors such as material flow and strength. We can custom fabricate your metal sheets or coils to contain the precise open area percentage that will provide the results you need, while also providing maximum durability.
Applications & Benefits of Custom Punching
There are a variety of reasons why a company may choose a custom perforated metal product over an off-the-shelf alternative. Custom metal punching allows you to specify exactly the hole size, pattern and open area percentage, the type of metal and a range of other options. This allows for greater overall design flexibility.
- Many of our clients come to us from highly specialized applications such as oil and gas exploration, and manufacturing, where filtration and screening processes demand custom perforated solutions.
- Custom perforated metal products also possess unique architectural value — often, architects will go with a custom product to give their building a look that stands out, or to work around limitations imposed by other materials.
- Whatever your application, custom metal punching services from Houston’s Marco Specialty Steel are the best way to ensure a finished product that delivers the performance, look and characteristics you require of it.
Understanding the Costs
Customized products inevitably cost more than premade solutions. Here’s a rundown of the main costs associated with our custom metal punching services:
- Raw materials: Specialized materials such as stainless steel or aluminum will be more expensive, particularly when bought in small quantities for a short order run.
- Tooling: Punch presses may use standard size tool and die kits, or they may require the development of a new mold, which will add to costs.
- Machinery: Hourly costs associated with running a punch press include labor, maintenance and electricity, as well as the amortized purchase price of the machine itself.
Understanding what’s involved in the cost of custom metal perforation is important when budgeting for a project. Let a Marco representative help you run the numbers and determine the most economical solution for your requirements.
Why Choose Marco for Your Perforated Metal Custom Punching Needs?
Marco Specialty Steel has been providing custom metal fabrication solutions since 1992. We understand the challenges that companies face, and can work with them to develop the right product for their applications. Our team includes knowledgeable, experienced design professionals who are willing to go the extra mile to help our customers achieve their project goals. We can even work with your existing blueprints and drawings, so feel free to upload them and we’ll put them to good use.
And if you’re concerned about having your project completed as quickly as possible, Marco Specialty Steel can provide a lightning-fast turnaround time — even for custom projects! We are available 24/7 for rush turnaround times.