Made-to-measure perforated sheets – custom perforations manufactured with precision
Standard perforated sheets off the shelf don’t suit your project? At BVS Blechtechnik, we manufacture perforated sheets exactly to your requirements – with individual hole patterns, complex geometries and free-standing edges. As a specialist for custom-made sheet metal solutions, we also realize the most demanding special perforations with the highest precision.
Whether individual items or small batches: Our production technology enables flexible solutions for projects where standard products reach their limits. We combine punching and laser cutting according to requirements to achieve optimum results. We guarantee accuracy of fit and flatness with inspections during production.
Your advantages: Maximum design freedom, cost-effective production even for small quantities and short throughput times. We process steel, stainless steel, aluminum and other sheet materials in thicknesses from 0.5 to 3 mm.
What makes made-to-measure perforated sheets special?
Customized perforated sheets differ fundamentally from industrially manufactured standard perforated sheets. While standard products specify fixed hole patterns, pitches and material thicknesses, individual production enables customized solutions that are precisely tailored to technical and design requirements.
Standard perforated sheet vs. customized production
Standard perforated sheets have predefined hole patterns, pitches and material thicknesses and are suitable for applications without special requirements. Customized perforated sheets, on the other hand, are manufactured on a project-specific basis. Hole shape, hole size, hole spacing, edge design and component geometry can be freely defined and enable solutions that cannot be implemented with standard products.
Complex geometries and special shapes
Our production department produces complex perforated sheets with asymmetrical patterns, varying hole diameters, combined hole shapes or curved contours. We also produce three-dimensionally formed perforated sheets as complete assemblies. Our vertical integration really comes into its own when it comes to demanding projects.
Logos and free-standing elements
Perforated sheets with free-standing edges or integrated logos are one of our special areas of expertise. Unperforated areas allow logos, lettering or graphic patterns to be integrated directly into the component. This results in functional products with high design standards, for example for facades, partition walls or furniture.
Technical possibilities and limits
Transparency about feasibility and technical limitations is the basis of any professional collaboration. At BVS, we work within a wide range of parameters and advise you openly on the possibilities and limitations of your project.
Sheet thicknesses: 0.5 to 3 mm
Depending on the material and process, we process sheet thicknesses from 0.5 to 3 mm. Stainless steel up to 3 mm can be punched and lasered without any problems, while laser cutting is often recommended for aluminum from approx. 2 mm. Very thin sheets (<0.8 mm) can be deformed by the process energy – here we can advise you on the optimum production strategy.
Hole diameter: From 1.5 mm
When punching, the smallest hole diameter that can theoretically be realized is 1.5 mm and the following guideline applies: The hole diameter should at least correspond to the sheet thickness in order to avoid tool breakage and material cracks. This limit results from the tool geometry and the material properties. For smaller diameters or particularly intricate hole patterns, we use laser cutting, which enables more precise and smaller structures. However, thermal effects and web widths limit the feasibility of micro-perforations. The choice of process depends on the hole diameter, sheet thickness, quantity and cost-effectiveness. We can advise you on the optimum process for your project.
Punching vs. laser cutting
Punching is suitable for high quantities and standardized hole shapes such as round or square holes. It is economical, fast and produces clean hole edges. However, special perforations such as triangles, hexagons or slotted holes require special tools, which increases costs for small quantities. Laser cutting works without tools and enables almost any hole shape without additional tool costs. It is ideal for prototypes, small series and complex geometries. We often combine both processes to achieve an optimum balance between quality and cost-effectiveness, for example to economically punch series hole patterns and laser-cut complex contours or logos in the same component.
Special perforations for special requirements
Special perforations go beyond standard round perforations and enable individual solutions if technical or design requirements cannot be met with standard perforated sheets.
- Special hole shapes such as square, rectangular, triangular, hexagonal or slot-shaped perforations influence permeability and design. Special tools are required for punching, while laser cutting also makes individual pieces economically feasible.
- Individual hole patterns enable freely designed arrangements with varying distances, hole densities or organic shapes. Applications range from acoustically optimized components to decorative
- Façade components. CAD data is transferred directly to production.
Combined perforations within a component allow different hole shapes, sizes and densities for functional zones. Such solutions are often used in acoustic panels, filter elements and façade construction.
Flatness and accuracy of fit
Ensuring flatness is a key challenge in perforated sheet production. Punching or laser cutting releases stresses in the material that can lead to warping. At BVS, we work with tried-and-tested processes to deliver predictable, precisely fitting components.
Punching challenges
Material is removed during the perforation process, which changes the internal stresses in the sheet. The material tends to warp, especially with high hole area percentages or thin sheets, particularly from a hole percentage of >40%. We discuss design alternatives for extremely high removal rates. The heat generated during laser cutting can also promote deformation. These effects can be minimized by suitable process parameters, but cannot be completely avoided.
Post-processing on the straightening machine
To ensure flatness and accuracy of fit, we straighten perforated sheets on special straightening machines. This work step compensates for deformations and ensures that the component complies with the required tolerances. The design of the processing is adjusted so that the finished component corresponds exactly to the specifications after straightening. Measurements during production check the flatness and document compliance with the specifications.
Constructive optimization
Distortion and deformation can be minimized as early as the design phase. We reduce process effects through suitable hole patterns, optimized edge distances and the selection of the appropriate manufacturing process. Our design engineers check your drawings for production-compatible design and, if necessary, suggest adjustments that increase quality or reduce costs without compromising function.
Areas of application for customized perforated sheets
Customized perforated sheets are used in numerous industries where standard solutions are not sufficient. The spectrum ranges from technical functional components to high-quality design elements.
- Façades and architecture: Perforated sheets are used as design and functional façade elements for sun protection, ventilation and privacy protection and allow a high degree of design freedom thanks to individual perforated patterns, logos or lettering. For free-standing logo elements, we recommend – depending on the material – minimum web widths of 1.0 to 1.5 mm and a defined inner radius design to avoid burr formation and material weakening. Materials such as stainless steel or anodized aluminium ensure durable, low-maintenance surfaces, for example for façades, balustrades or acoustic ceilings.
- Mechanical and plant engineering: In mechanical and plant engineering, perforated sheets serve as protective grilles, ventilation elements as well as sieve and filter components and enable defined air passages, particle selection and sound absorption through precise perforations. We also produce weight-optimized lightweight solutions as integrated assemblies including forming and welding.
- Interior fittings and design: In interior fittings, perforated sheets are used for room dividers, furniture fronts, door panels or lights and combine a filigree look with high stability. Individual perforations and surface finishes such as powder coating or anodizing expand the design possibilities.
- Filter technology and sieve production: In filter technology, precise perforations enable exactly defined degrees of permeability for gas, liquid and solid filters as well as sieves for industry, food processing and chemicals. The choice of material depends on media resistance, temperature requirements and corrosion protection.
What we need for your calculation
For a reliable feasibility analysis and a precise quotation, we need meaningful documentation on your project. The more detailed your information, the faster we can assess feasibility, costs and delivery times.
- Technical drawings and 3D models provide the basis for precise production. Fully dimensioned drawings with tolerances, material and surface specifications are ideal. Alternatively, we process 3D data in neutral formats such as STEP, IGES or DXF, regardless of the software used.
- Sample parts can serve as a basis for subsequent production or further development. We measure the component, create the technical documentation and manufacture reproducible components, including reverse engineering of complex geometries.
- Material specifications determine function, appearance and cost-effectiveness. You specify the desired material or the requirements, we advise on suitable materials and take into account criteria such as strength, weight, corrosion protection, weldability and surface treatment. Steel, stainless steel and aluminum are among the standard materials; we procure other materials on a project-specific basis.
From inquiry to production
The path to your individual perforated sheet is clearly structured and transparent. We accompany you from the initial idea to the finished component and keep you informed of all project steps on request. After receiving your documents, we check the technical feasibility, evaluate the geometry, material, production process and tolerances and clarify any open points directly with you. If necessary, we recommend production-related adjustments to optimize costs or quality. This feasibility analysis is free of charge for you.
On this basis, we prepare a detailed quotation with prices, delivery times and key technical data. For complex projects, we can also produce a sample component to test its function, accuracy of fit and appearance. After your approval, series production begins
During production, measurements are taken to ensure compliance with all specifications. After the final quality control, we deliver your components on time – including the agreed test reports and certificates.
Frequently asked questions (FAQ)
What is the difference between standard perforated sheets and made-to-measure perforated sheets?
Standard perforated sheets have fixed hole patterns, pitches and material thicknesses and are available at low cost, but cannot be customized. Customized perforated sheets are manufactured individually, whereby the hole shape, size, spacing, edge design and geometry can be freely defined. This allows technical and design requirements to be implemented that are not possible with standard products.
Which hole shapes are possible and do I need a special tool?
In addition to round perforations, square, rectangular, triangular, hexagonal or slotted shapes are also possible. Punching requires a special tool, whereas laser cutting works without tools. Laser cutting is therefore usually the more economical solution for prototypes and small series.
From what quantity is individual production worthwhile?
Individual perforated sheets can be produced from quantities as low as 1. There are no tool costs for laser cutting, while special tools for punching are amortized from medium quantities. We determine the most economical production variant for each project.
How can I ensure that my perforated plate remains flat after perforating?
Flatness is ensured by optimized hole patterns, suitable production parameters and the subsequent straightening of the components. Adapted processing and measurements during production ensure compliance with the specified tolerances.
What documents do you need for a binding offer?
Ideally, you should provide dimensioned drawings with tolerances, material and surface specifications. Alternatively, we can also work with 3D models or sample parts. Information on the quantity, delivery time and special requirements support a precise calculation.
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