Perforated metal works well in these applications because three variables can be controlled precisely: open area, hole size and pattern, and material. Getting the balance right is what separates a functional part from a decorative one.
Open area, the percentage of the surface occupied by holes, is the primary lever. For ventilation, a higher open area allows more airflow at lower resistance. For acoustics, the open area is tuned deliberately, often in combination with a cavity and an absorptive material behind the panel, so that the assembly targets specific frequencies. A perforated facing over a backing cavity behaves as a tuned absorber, which is why the exact open area and hole spacing matter so much.
Hole size and pattern come next. Small, closely spaced holes give a fine, uniform appearance and predictable acoustic behaviour, while larger holes maximize raw airflow. The pattern, whether round, square, or a specialized geometry, affects both performance and how the panel can be formed or mounted. Consistency across the whole panel is essential, because irregular perforation produces uneven airflow or unpredictable sound absorption.
Material determines whether the part survives its environment. Aluminum is favoured in aerospace for its strength-to-weight ratio, which keeps components light without sacrificing rigidity. Stainless steel is chosen where higher temperatures, moisture, or corrosion resistance are required, such as in engine-adjacent or exterior applications.
Two further factors matter in an aerospace context specifically. The first is tolerance: acoustic and airflow calculations assume the panel matches the specification closely, so hole diameter and pattern registration must hold across production. The second is documentation and traceability, so that the material and its properties can be verified.
When specifying, it helps to lead with the functional goal. If the target is airflow, state the volume and allowable pressure drop. If the target is acoustic, describe the frequencies of concern and the assembly the panel sits within. From there, a perforator with custom die capability can recommend the open area, hole size, and material that meet the requirement, and produce tooling for a pattern that is not already in stock.