Custom Perforated Façade Cladding – OBI DIY Store
Complete engineering and production within 4 weeks
For this project, Ten Brinke approached Pillen Sheet Metal with the request to take care of both the engineering and the production of perforated façade cladding made from sheet material. The façade panels were intended for a new retail façade for OBI, where appearance, functionality, and planning were all critical factors.
The request from Ten Brinke
Ten Brinke was looking for a single partner capable of handling the entire process: from engineering through to the production of custom façade panels. The objective was a technically reliable and visually distinctive façade solution, delivered within a tight schedule.
The end client’s requirements
The end client wanted a façade with a modern appearance, based on perforated sheet metal, featuring a seemingly random perforation pattern.
Key requirements included:
- all panels having the same execution, shape, and overall appearance;
- each panel featuring a unique perforation pattern;
- a calm and consistent overall façade appearance.
Technical challenge & our solution
The main challenge was combining aesthetics, manufacturability, and lead time. In total, 122 unique façade panels were engineered and produced by us, within a total lead time of just 4 weeks.
Our approach included:
- Development of a random perforation pattern, distributed across 122 unique panels;
- Parametric design of the panels, with a maximum sheet size of 3000 × 1500 mm;
- Control of stresses and deformation during laser cutting;
- Keeping perforations clear of bending zones to prevent distortion during forming;
- Ensuring high surface quality:
- no deep scratches
- no burrs
- careful deburring to achieve a smooth, uniform finish after powder coating
To ensure manufacturability, several test panels were produced. Based on these tests, the final perforation pattern was defined as:
- Hole diameter: Ø20 mm
- Centre-to-centre distance: 25 mm
Machinery used
For the production of the façade panels, the following machines were used:
- Laser cutting: Bodor fiber laser
- Deburring: Timesavers deburring machine
- Bending: Safan E-Brake press brake
Material selection
Aluminium was selected due to:
- its low weight per panel;
- excellent processability for laser cutting and bending;
- durability and suitability for façade applications in combination with powder coating.
Project complexity
This project involved a high level of complexity due to:
- a high degree of variation (no series production; each panel was unique);
- tight tolerances for fit and installation;
- a short, fixed lead time of 4 weeks;
- intensive coordination between engineering, production, powder coating, and logistics;
- collaboration with Coates for powder coating and packaging.
Why did Ten Brinke choose Pillen Sheet Metal?
The decisive factors were:
- In-house engineering capability combined with production under one roof;
- Proactive involvement in developing solutions, including for operable windows, such as:
- hinge mounting
- required clearance and tolerances for opening windows and vents
- Reliable delivery despite the tight schedule. Numbering of all panels for easy and error-free installation.
- Careful packaging of the panels to ensure safe transport.
