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Punching is one of the most economical fabrication options for aluminum extrusion products to create multiple shaped holes in a variety of products. For example, it is commonly used in cladding, rolling gate profiles, and cable trays.
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In recent years, there is a surge in low-cost desktop-size home/DIY/High School level CNC, milling machine, router and 3D printers (common 3D motions parts, just the 'head' differs) Hundreds of companies do sell assembled unit and/or kits. I do not have hands-on experience on this myself and cannot offer solid help.
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Shop Expanded & Perforated Sheet Metal on Amazon. Perforated sheet metal is created by punching a series of holes in a solid material. The holes in perforated metal sheets are typically round, square, or slotted, but other patterns include hexagonal, Grecian, and cane.
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Bend allowance is the amount of metal to be added to the total layout. The most important considerations when bending metal is the min. bend radius. When bends are made smaller than the required min. radius, metal will crack at the outside heel of the bend.
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Then as with the metal rod fixings, enlarge these new holes in the flat bar to 5mm but this time, countersink the holes on the TOP of the bar. Finally, using M5 x 25mm, countersunk allen bolts through the bottom face of the flat bar, through the electrical stand offs and into the metal rod.
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Peddinghaus offers the Anglemaster-663 for fabricators that need to automate punching, shearing, and marking for angle and flat bar. The machine can accommodate shaped holes such as squares, rectangles, obrounds, and slots, including a feature that allows nibbling of material.
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The radius that the metal is bent over should be machined to product specifications. The female radius on the forming section should be ground to 1x metal thickness larger than the inside bend radius and ground back to a 20-degree angle from the midpoint of the tangents of the radius (this is a relief angle, and its accuracy is not critical).
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