Solvaro
Perforated metal components
Development and production
are our core competences
Perforated metal components manage a demanding balancing act between technical, functional and optical requirements in numerous technical applications: They must be as air-permeable as possible, but should reliably filter unwanted particles out of the air. The filigree webs of the perforated sheet are sometimes just 0.5 mm thin – but they have to withstand high loads and be as stable as possible. At the same time, of course, the component must also meet the user’s visual requirements.
The production process for perforated metal components is correspondingly complicated: Sheet metal is perforated, deburred, deep-drawn and finally coated in a multi-stage process that requires a great deal of sensitivity and experience. But the effort is worth it: perforated metal components from Solvaro meet the highest demands in terms of air permeability, filter function, stability and aesthetics. The application spectrum of our components is correspondingly versatile and ranges from agricultural and construction machinery, buses and trucks to server cabinets.
Air permeability
The core competence and main task of perforated metal components is air permeability: air flows through the free cross-section of the components, reliably dissipating process heat from the interior and thus cooling engines, servers or other equipment. The energy efficiency and performance of engines in commercial vehicles, for example, depends to a large extent on the cooling concept: free cooling by air offers the advantage of natural, efficient heat transport without the use of energy. In addition, no liquid cooling media such as water or coolant are used for waste heat transport.
The free cross-section of the perforated plate is decisive for the efficiency of air cooling. This depends largely on the type of perforation selected, with hexagonal and round perforations predominating. Hexagonal perforations achieve a free cross-section of up to 85 % and thus allow a highly efficient air supply. The round perforation, as a somewhat cheaper alternative, offers the possibility of providing hole-free zones as well as straight or staggered perforation.
Filter function
Especially in the automotive sector, it is important that perforated metal components not only allow air to pass through, but also reliably filter out unwanted particles at the same time. For example, dust, stones, litter during harvesting pose a danger to the sensitive engine compartments of tractors or harvesters. Likewise, excavator engines must be protected from dirt and soil, and buses and trucks must be protected from stone chips or rubbish from the road.
Even the smallest particles can lead to blockages, damage or rust deposits in the engine interior – the fine, net-like perforation of the perforated metal components therefore serves as a barrier for such particles and protects the interior from external influences.
Perforated metal components also have the task of filtering unwanted particles outside of vehicle technology. For example, air filters are used in loudspeakers to protect the sensitive electronics in the interior. Whether for filtering liquids in washing machine drums, whey flow in the food industry, oil filters or substance separation in the pharmaceutical industry: perforated metal components reliably prevent the passage of unwanted particles.
Stability
The inherent strength of the metal sheet is partially affected by the perforation. It is therefore important to minimise this loss of strength in the manufacturing process. A hexagonal perforation achieves exactly this: The shape of the perforation, which is modelled on a honeycomb, ensures extremely low impairment of the inherent strength despite the high free cross-section.
During the forming process, the stability is then even largely restored, so that the perforated sheet is once again as resistant as solid material. Processes such as folding, deep drawing or beading are decisive in giving the perforated sheet the desired stability. All component contours such as edging, beading or deep drawing therefore not only serve to produce the desired geometry for installation, but also provide additional component stability.
For developers, it is important to precisely match the production of the perforated component to the aforementioned requirements. Essentially, the balancing act between the required air passage and the necessary stability has to be mastered. The efficiency and performance of commercial vehicles such as tractors depends to a large extent on the size and permeability of the tractor bonnet – but at the same time it must be stable enough to protect the engine from external influences such as stone impacts at all times.
Through years of experience and intuition, Solvaro’s developers succeed in combining all relevant parameters such as component shape and size, material thickness, perforation and forming in such a way that the stability required for the application is provided.
Weight reduction
The larger the free cross-section, the lower the weight. Thanks to this simple basic rule, perforated metal components provide noticeable advantages in terms of energy efficiency and fuel consumption in all mobile applications. A perforated metal component with hexagonal perforations, for example, achieves a weight reduction of 85 % – compared to solid material, the vehicle engine therefore also has to move 85 % less mass. This not only reduces fuel consumption, but also the vehicle’s CO2 emissions. Another positive side effect: thanks to the weight reduction, lightweight vehicles can accelerate faster and are more manoeuvrable in use.
Design freedom
Today, perforated metal components not only have to fulfil complex technical requirements, but also meet the highest visual demands. For example, grilles are placed on the front of commercial vehicles, where they are directly in the viewer’s field of vision. Especially in vehicle technology, the striking appearance of the vehicle front is often a decisive factor in the purchase – all components must therefore meet the highest requirements in terms of aesthetics and design.
During production, the design specifications of the OEMs must be fulfilled through a skilful choice of component shape, size and perforation as well as customised deep drawing tools. Ideally, the technical requirements for air permeability, filter effect and stability are elegantly combined with the visual requirements for shaping and design. For example, moulded recesses for the brand logo can be integrated, certain shapes associated with the brand can be taken up or attractive, visually seamless transitions to adjacent plastic parts can be produced.