introduction
A custom perforated sheet is not just a metal sheet with holes. It is a complete engineering system. Every step affects the final quality. Many buyers do not know the factory process. I work at Xiongqian. Today, I will walk you through our perforated sheet manufacturing process.
We break the process down into 10 key steps. This will help you avoid many sourcing problems.
Step 1: Engineering Review
The salesperson sends the drawing to the engineer. The engineer checks the hole size. The engineer calculates the open area. The engineer checks the margin. A narrow margin tears the metal. The engineer optimizes the layout. A good layout reduces waste. This saves money for the client.
Step 2: Material Prep
The purchasing team buys raw metal sheets. Common materials are carbon steel, aluminum, and stainless steel. The QC inspector tests the thickness. Workers load the coils onto a leveling machine. This step is very important. An unlevel sheet bends during punching. The machine removes internal stress. The sheet becomes completely flat.
Step 3: Tooling Matching
The technician checks the tooling library. The factory has hundreds of molds. The technician looks for the right mold. For special perforated metal mesh patterns, we make new tooling. This takes 3 to 5 days. The technician tests the clearance between the punch and the die. A large gap creates burrs. A small gap breaks the mold.
Step 4: Sampling
Workers use the CNC punch press to make samples. The machine makes the holes. The engineer measures the hole size. The standard is ±0.1 mm. The engineer checks the edges for burrs. The sample shows the real look to the client. It also locks the machine parameters.
Step 5: Client Approval
The client receives the samples. The client tests the strength and flatness. The client signs the approval. The planning team schedules mass production. The production team prepares the machines. The machine program is now locked.
Step 6: CNC Punching
The operator loads the sheet onto the CNC turret punch press. The machine punches holes at high speed. The machine moves the sheet automatically. The operator watches the machine closely. The operator listens to the sound. The operator randomly checks the finished parts.
Step 7: Surface Finishing
The punching process leaves burrs on the edges. Workers put the sheets into a deburring machine. The machine smooths the edges. For EV battery parts, we use precision grinding. The burr height stays below Ra≤0.8μm. Workers apply powder coating or galvanizing next. The coating thickness is 60 to 80 μm.
Step 8: Quality Control
The QC inspector performs the final check. The inspector measures the dimensions. The inspector counts the holes. The inspector looks for surface scratches. The inspector checks the flatness. The bending per meter must stay below 2 mm. The inspector saves all records. We follow the ISO 9001 system.
Step 9: Scratch-Proof Packaging
The metal surface scratches easily. Workers place moisture-proof paper between the sheets. Workers put the sheets on wooden pallets. Workers secure the load with steel straps. Sea freight requires rust-proof bags. Good packaging protects the product.
Step 10: Shipping & Aftersales
The logistics team arranges the container. The team calculates the volume. We provide the Material Test Certificate (MTC). We also provide the inspection report. Choosing reliable perforated metal sheet suppliers guarantees aftersales support. We handle any quality issues after delivery.
Summary of the 10 Key Steps
| No. | Process Step | Main Department | Core Tech & Quality Standard |
|---|---|---|---|
| 1 | Drawing Review | Engineering | Optimize layout, calculate open area, check feasibility |
| 2 | Material Prep | Purchasing / Warehouse | Material test, coil leveling (remove stress) |
| 3 | Tooling Matching | Technical | Mold library matching, clearance test |
| 4 | Sampling | Production | Set machine parameters, First Article Inspection (FAI) |
| 5 | Client Approval | Client / Sales | Confirm look, size, open area, and flatness |
| 6 | CNC Punching | Punching Workshop | High-speed auto punching, prevent bending |
| 7 | Surface Finishing | Finishing Workshop | Deburring (Ra≤0.8μm), powder coating or galvanizing |
| 8 | Quality Control | QC Department | Size measurement, flatness test, surface check |
| 9 | Packaging | Packing Team | Moisture-proof paper, wooden pallet, anti-rust |
| 10 | Shipping | Logistics | Container loading, provide MTC, aftersales tracking |
Source: ISO 9001:2015 Quality Management System documents and Xiongqian production standards.
FAQ
How long does custom perforated sheet manufacturing take?
The factory ships the goods in 7 to 10 days if molds are ready. It takes 15 to 20 days for new tooling. Peak seasons might take a bit longer.
Why does the sheet bend after punching?
The punching process releases internal stress. We use a leveling machine in Step 2. We also use CNC machines with tension control. This minimizes bending.
What is the hole tolerance?
Standard parts have a ±0.1 mm tolerance. Precision parts have a ±0.05 mm tolerance.
What is the normal thickness of powder coating?
Indoor powder coating is 60 to 80 μm thick. Outdoor projects need fluorocarbon paint or galvanized coating.
How do you ensure mass production matches the sample?
We use the exact same mold. We lock the machine program. The inspector checks samples every 100 pieces.
Conclusion
A good perforated sheet needs 10 strict steps. The process starts with material leveling. The process ends with scratch-proof packaging. Every step affects the final quality. Xiongqian is a professional perforated sheet manufacturing partner. Send your drawings to us. We will deliver a perfect product.
