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Custom perforations on metal panels are openings cut or punched to deliver a specific combination of screening, ventilation, daylight control, solar filtering, appearance, or equipment concealment. The reliable way to order them is to coordinate the pattern, open area, metal, thickness, panel dimensions, finish, forming, and fixing as one project specification—not to select a hole pattern in isolation.
A useful fabrication brief states the intended outcome, supplies a drawing or image, and identifies quantities and sizes. The fabricator then confirms achievable geometry, material, tolerances, folding, mounting, lead time, and price. Structural, wind, fire, acoustic, weather, ventilation, and code performance still need project-specific design and approval.
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One free scan finds every outdated or missing driver and matches the right update for your exact hardware.Free scan · exact hardware matchWhat are custom perforations on metal panels?
A perforated panel has a deliberate field of openings in sheet metal. “Custom” means the opening geometry, spacing, orientation, borders, dimensions, or layout is changed for a particular project rather than taken unchanged from a standard stock sheet. A design may use round, square, slot, rectangular, decorative, or image-derived openings, provided the selected fabricator can produce them in the chosen alloy and thickness.
Custom perforated metal is used for facade screens, rainscreen or cladding features, sunshades, balustrade infill, ceilings, feature walls, plant and equipment screens, ventilation grilles, and interior partitions. CASA Group describes supplying material, perforation, and folding together, while Architectural Façade Solutions (AFS) describes flat, curved, and folded faces in a concealed hook-on facade system. Those examples show why the panel face, its formed edges, and its support system should be designed together.
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Start with the job the panel must perform. A screen intended to hide plant at close range may need a different hole size and viewing angle from a facade intended to admit daylight. A ceiling panel may prioritise visual rhythm and access, whereas a sunshade may require a solar-control analysis. The pattern is the visible part of a larger assembly.
Which pattern details belong in a fabrication brief?
Pattern names such as “perforated,” “slotted,” or “decorative” are not complete specifications. Give the supplier the geometry and the way it is laid out so the quoted open area and appearance can be checked.
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|---|---|---|
| Hole shape | Round, square, slot, rectangle, custom contour, or image-based artwork | Changes visual character, tooling or programming, edge strength, and cleanability. |
| Hole size | Diameter or length and width, with units | Controls sightlines, apparent openness, and the remaining metal between openings. |
| Pitch or spacing | Centre-to-centre spacing or clear gap | Allows the fabricator to reproduce the pattern and calculate open area. |
| Arrangement | Straight-line, staggered, graduated, random, or image-derived | Alters the visual field and the amount of metal around each opening. |
| Orientation | Landscape, portrait, diagonal, or a defined rotation | Can affect views, perceived privacy, drainage paths, and the direction of slotted openings. |
| Open area | Target percentage and the calculation basis | Provides a measurable design intent, but does not by itself prove airflow, acoustic, structural, or weather performance. |
| Margins and borders | Solid perimeter, edge distance, corner treatment, and any unperforated zones | Needed for stiffness, folded returns, fasteners, cassette edges, and clean visual termination. |
Send a dimensioned drawing whenever possible. CASA specifically asks for a pattern, drawing, or image together with quantities and sizes, and says it can provide project samples and quote material, perforation, and folding. An image can communicate the intent, but the final drawing must define scale, repeat, borders, and panel orientation.
How should open area be specified and interpreted?
Open area is the percentage of a panel face occupied by holes. It is useful for comparing pattern options, but it is not a universal performance rating. The same nominal percentage can look and behave differently when the hole shape, pitch, thickness, border, frame, or installation angle changes.
Published manufacturer examples illustrate the range. Morin’s perforated-panel portfolio lists six example patterns with open areas of 10%, 23%, 23%, 30%, 33%, and 40%. The ATAS International Gaten Series brochure lists six examples at 40%, 23%, 23%, 51%, 40%, and 33%. The repeated percentages represent different geometries, not duplicate performance claims; these figures are pattern specifications from the respective catalogs, not market averages.
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| Published source | Example open-area figures | How to use the information |
|---|---|---|
| Morin perforated-panel portfolio | 10%, 23%, 23%, 30%, 33%, 40% | Use as reference points when discussing visual density and candidate patterns; confirm the exact hole and spacing combination in the current catalog. |
| ATAS Gaten Series brochure | 40%, 23%, 23%, 51%, 40%, 33% | Use to compare named pattern options and investigate custom availability; obtain current shop drawings and engineering data for the project. |
Ask the supplier to show how the percentage was calculated and whether it excludes solid borders, folds, rails, or framing. Then review a physical sample at the intended viewing distance. A pattern that looks open on a small catalog swatch can appear much denser on a full-height facade, especially when backlighting, interior lighting, or a dark backing changes contrast.
Which metal, thickness, finish, and size should you choose?
Material selection depends on exposure, appearance, forming requirements, adjacent metals, maintenance expectations, and the supplier’s available stock. CASA lists copper, zinc, aluminium, COLORBOND steel, brass, and stainless steel, with powder coating available for aluminium and steel. AFS lists aluminium, stainless steel, copper, and zinc perforated faces with coated or anodized finish options. These are supplier-specific offerings, not a universal list.
CASA states a 0.55–2 mm thickness range, subject to the material available, and a maximum processing size of 4000 × 1750 mm. Treat both figures as CASA’s stated capability, not a market-wide limit. Other fabricators may have different sheet sizes, gauges, minimum features, or forming constraints.
For every quote, identify the alloy or grade, nominal thickness, finish system, colour reference, gloss or texture if relevant, and the exposure environment. Check galvanic compatibility where dissimilar metals touch, especially around fasteners, rails, flashings, and drainage paths. Confirm whether the finish is applied before or after forming and how cut edges, folded returns, and repaired areas are protected.
Dimensions should include the overall panel, perforated field, solid margins, folds, returns, cassette depth, and orientation marks. State quantities by panel type and include a replacement allowance if access is difficult. A large perforated sheet may need intermediate support or a formed cassette to control deflection; that decision belongs in the engineered assembly rather than being inferred from the open-area percentage.
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Should the panels be punched, laser-cut, flat, or folded?
CASA documents both CNC punching and laser cutting. The appropriate process depends on the geometry, repeat quantity, material, thickness, edge quality, and supplier equipment. The reviewed sources do not establish a universal cost, speed, or tolerance advantage for one process, so request a process recommendation and written limits for your exact design.
Punching is commonly considered for repeating patterns, while laser cutting can support more intricate or image-based layouts; those are general process descriptions, not a guarantee that a particular fabricator will use either method for your job. Ask about minimum hole or web size, heat effects, burrs, dross, distortion, nesting, and allowable tolerances in the selected metal.
Forming is a separate design decision. Panels can remain flat, or be folded into returns, cassettes, trays, blades, or other profiles. Folding changes the developed blank, the location of the perforated field, corner details, and the way the panel is supported. Provide a section and an unfolded pattern so the supplier can confirm that holes will not run into bend lines, fastener zones, or required edge margins.
AFS describes a concealed hook-on arrangement using rails and brackets. That kind of system can provide a clean face and access for replacement, but rail locations, substrate capacity, movement joints, drainage, and panel removal sequence must be engineered for the building. Do not assume that a hook-on detail, clip, or cassette shown in a brochure is suitable without project confirmation.
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How do you prepare a custom perforated-panel order?
Give the project team and fabricator enough information to price and engineer the same thing. The following sequence reduces redesign and prevents a visually attractive pattern from failing at the fixing or approval stage.
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- Define the outcome. Write whether the panel is for visual screening, privacy, daylight filtering, solar control, ventilation, acoustic treatment, safety infill, equipment concealment, or a combination. Note the important viewing directions, lighting conditions, and maintenance access.
- Set the design envelope. Provide elevations, plans, sections, panel zones, quantities, maximum panel size, support spacing, solid borders, folds, returns, and any curved geometry. Mark joints, corners, doors, access panels, and interfaces with other cladding.
- Select a candidate pattern. Specify hole shape, dimensions, pitch, arrangement, orientation, and target open area. If the design is image-based, supply the source artwork plus the desired repeat, scale, and minimum feature size.
- Choose metal and finish. State alloy or grade, thickness, coating or anodizing, colour, texture, corrosion exposure, and compatibility with adjacent materials. Ask the supplier to confirm current availability and edge-treatment requirements.
- Request a manufacturability review. Have the fabricator check tooling or laser programming, minimum webs, edge distances, bend lines, nesting, tolerances, flatness, and panel-size limits. CASA’s published capability, for example, includes 0.55–2 mm material-dependent thickness and processing up to 4000 × 1750 mm; another supplier may differ.
- Review a sample or mock-up. Use the intended finish and, where scale matters, a representative hole field. Check visibility through the screen, shadow pattern, colour, reflections, backlighting, and the appearance of joints and solid borders.
- Coordinate the assembly. Approve rails, brackets, clips, fasteners, substrate, movement allowances, drainage, ventilation paths, access, and replacement strategy with the facade or building-envelope designer. Record whether the panels are flat, folded, curved, or cassette-formed.
- Complete engineering and approvals. Obtain project-specific checks for wind and structural loads, vibration, impact or guard requirements, fire behaviour, corrosion, weathering, acoustics, thermal or solar effects, ventilation, and local code provisions. Identify who is responsible for calculations, shop drawings, testing, and sign-off.
- Lock the commercial scope. Ask for separate lines for material, perforation, forming, finish, packing, delivery, installation, samples, engineering, and replacement panels. Confirm lead time, quote validity, delivery location, installation scope, and the procedure for approving substitutions.
What performance questions still need project engineering?
Open area alone cannot establish whether a panel will withstand wind, meet a guard or balustrade requirement, deliver a particular airflow, reduce noise, control solar gain, resist fire, or remain weather-tight. The supporting frame, fasteners, backing wall, cavity, seals, drainage, and local exposure are part of the performance calculation.
For an exterior facade, coordinate wind pressure, suction, panel span, fixing pull-out, thermal movement, water management, and corrosion category. For a sunshade, assess orientation, seasonal sun angles, glare, and the effect of the panel on daylight and cooling loads. For ventilation or plant screening, confirm the free area of the complete assembly, including frames, filters, acoustic lining, and any backing mesh—not just the decorative face.
For balustrades, guards, or locations accessible to children, obtain the applicable code interpretation and impact or climbability assessment from the responsible professional. For fire-rated or smoke-control applications, use tested assemblies and approved details; a catalog pattern is not a fire rating. Acoustic claims likewise require data for the actual panel, cavity, absorber, and backing construction.
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Compare documented capabilities against your brief, then ask each supplier to confirm the items that are project-specific. Supplier literature is useful for narrowing options, but it is not an independent performance comparison.
| Supplier example | Documented capability | Questions to confirm |
|---|---|---|
| CASA Group (Australia) | Custom facade, screen, ceiling, and feature-wall panels; CNC punching or laser cutting; multiple metals; folding; samples; pattern, drawing, image, quantity, and size-based quote intake; 32 standard patterns; stated 0.55–2 mm range and 4000 × 1750 mm maximum processing size. | Current material and finish availability, tolerances, edge margins, formed details, delivery region, engineering documents, and installation responsibility. |
| Morin | Architectural wall and roof portfolio with example perforation patterns, suggested materials and gauges, and custom patterns for screens and sunshades. Its portfolio states that perforations are produced in-house, which it says can reduce costs and help lead times. | Current pattern library, minimum quantities, custom tooling or programming, gauge limits, finish options, samples, and project-specific lead time. |
| ATAS International | Gaten Series brochure with six example patterns, custom options, and related engineering and system components. | Current pattern availability, sheet and gauge limits, compatible attachment details, finish warranties, and calculations for the proposed assembly. |
| Architectural Façade Solutions | Q-PERF custom CNC-cut panels in flat, curved, or folded forms with concealed hook-on fixing. | Rail and bracket layout, substrate requirements, movement joints, panel dimensions, access, replacement method, and project engineering. |
Ask for current shop drawings, a sample, tolerances, finish data, installation details, and references for a comparable exposure or panel size. Do not infer that a supplier’s standard pattern, maximum sheet size, or mounting detail applies to a different alloy, thickness, region, or building.
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What commonly goes wrong, and how do you prevent it?
- The pattern is specified without a scale. A small visual may not show how the field reads at full height. Include hole dimensions, pitch, repeat, and a scaled elevation.
- Open area is treated as a guarantee of airflow or screening. Calculate the complete assembly, including frames and backing, and review sightlines from the actual approach paths.
- Holes run into folds or fasteners. Supply an unfolded blank and section details early; reserve solid margins and bend zones.
- The selected metal is unavailable in the required size. Ask for current stock, substitutions, and the effect of changing alloy or thickness before approving the design.
- Finish and adjacent metals are incompatible. Confirm coating, edge protection, fastener material, drainage, and corrosion exposure as one system.
- Panels are too large or flexible for the support layout. Have the engineer check span, deflection, vibration, thermal movement, and fixing capacity; consider formed returns or intermediate rails.
- Access and replacement are ignored. Document how a damaged panel, filter, light, or piece of equipment will be reached without dismantling unrelated cladding.
- A brochure detail is copied without approval. Treat catalog drawings as starting points and obtain signed project shop drawings and calculations for the actual substrate and loads.
What should the final approval package contain?
Before fabrication, assemble the approved pattern drawing, panel schedule, material and finish specification, developed blanks or CNC files, tolerances, edge and fold details, fixing and support drawings, sample sign-off, engineering calculations, test reports where required, installation sequence, and maintenance or replacement notes. Include the project location, exposure, delivery and installation scope, and the person responsible for each approval.
This package gives the contractor a controlled reference when panels meet corners, openings, movement joints, flashings, or other trades. It also makes substitutions reviewable: a change in hole size, alloy, gauge, coating, or rail position can be assessed for appearance and performance instead of being treated as an equivalent by default.
Is a custom perforated panel the right solution?
It is a strong fit when the project needs a repeatable visual language, controlled visibility, ventilation or daylight filtering, and a panel that can be formed and fixed as part of a coordinated facade or interior system. It is not a shortcut around engineering. The best result comes from a clear performance brief, a sample at real scale, supplier confirmation of manufacturability, and project-specific design of the supporting assembly.
Frequently Asked Questions
Can I order a custom perforated panel from a photograph alone?
A photograph can communicate the intended motif, and CASA says it accepts a pattern, drawing, or image for an initial quote. It still needs dimensions, repeat or scale, quantities, material, thickness, borders, and finish before fabrication files and a binding quotation can be prepared.
Does a higher open-area percentage always provide better ventilation?
No. Free area is reduced by borders, frames, rails, backing screens, filters, acoustic liners, and the angle of airflow. An engineer should calculate the complete assembly for the required pressure drop or ventilation duty.
Can perforated panels be used as a balustrade or guard?
They may be part of a guard system, but suitability depends on local code, opening limits, impact resistance, climbability, loads, and the supporting frame. Obtain the required assessment and approved details for the actual location rather than relying on a pattern percentage.
How do I keep an image-based perforation recognizable at facade scale?
Define the viewing distance, lighting direction, panel module, and minimum feature size before the artwork is converted into holes. Request a full-scale or representative mock-up, because thin webs, solid borders, joints, and shadows can change the image substantially.
What information should I send when requesting quotes from several fabricators?
Send the same dimensioned elevations and sections, panel schedule, pattern file or image, target open area, material and finish, folds, fixing concept, quantities, site location, delivery date, and required approvals to every bidder. Ask each to identify exclusions and assumptions so prices and lead times are genuinely comparable.
