I got a request from a customer for a "fine grille" on one soffit mounted
A/C vent over a counter-top/desk.
I showed him a sample of 1/2" x 1/2" aluminum return grille material, and he
wants the holes about half that size.
Yeah... I told him about reduced air flow, etc, but this is all about
cosmetics, and it's only one vent, not all of them.
I've dug around the web, and only found 1/2" cells and larger. Local
doesn't stock anything smaller.
Does anyone here know of a source for egg-crate style grille material in
1/4" openings? It could even be lighting grille material, cut to size. I
can figure out the escutchion to hold it on the boot, but I'm ready to
make a custom grille.
Honeycomb panels are used for RF shielding. For example:
As far as I know they are all custom made and cell size and size can be
specified. They likely to be costly for your application. I would look
around the surplus market. Key words are shielding, EMI, Honeycomb
panels, shielded rooms, waveguide below cutoff.
Nope.... all the shielding material is 1/8" cell. Too small for this app.
It would work OK, but I've been given the "1/4-inch command".
I checked out honeycomb core material for panels, and it is available in
1/4" cell, but the foil is only (max) 0.002" thick... much too fragile for
I've seen honeycomb AL material used on jet engines (P&W 4090 was the
last I saw), so somebody makes it. The difficult part is finding out who
and then being able to get a small piece.
If it's a one-off thing and the material is not critical you might
consider cutting the pattern into a mold of some sort and casting the
piece in a good filled epoxy material.
Well if you get desperate you could go to a kitchen supply store and buy
a large waffle grid, then mix up some polyester resin and some
fiberglass strands and pour/mold your own.
I have seen 1/4" used as speaker grill material on older speakers.
Aircraft spruce certainly doesn't make the honeycomb so further
searches may turn up the manufacturer, or wholesaler. Certainly other
dimensions are available commercially. I well remember making aileron
trim tab repairs for the Boeing 707 (KC-135) using the material and
IIRC we stocked it in various dimensions. I have a mate who does a lot
of composite work and will ask him, tomorrow, if he has a reference
for a supplier.
Bruce in Bangkok