Diamond Manufacturing operates North America’s largest fleet of full-width perforating presses. With up to 500-ton capacity, 84-inch feed width, and a 4,000-tool pattern library, they punch as many as 300,000 holes per minute while holding ±0.010-inch positional tolerances across coils or sheets up to ½-inch thick—delivering flat, production-ready perforated metal at any volume.

Metal Perforation is the controlled punching of uniform or custom-pattern holes into sheet or coil stock by means of roll-feed or step-feed presses. Continuous full-width perforators or sectional (zone) perforators create ventilation panels, filtration media, acoustic screens, architectural facades, and light-weight structural panels across ferrous and non-ferrous alloys. The process can run coil-to-coil, coil-to-sheet, or sheet-fed and may integrate inline leveling, lubricating, and cut-to-length blanking for high-throughput, burr-free production.

Metal Perforation

Supports high volume production demands, ensuring scalability and competitive cost for large-scale orders.

Meets the needs of medium volume production, offering cost efficiency for expanding product lines.

Designed for prototyping and small batch runs, allowing for rapid iteration and testing.

Optimized for low volume production, ideal for market introduction and specialized products.

Continuous coil-to-coil perforation using matched rotary punch and counter-rolls to produce uniform patterns across the entire strip width at line speeds up to 250 ft·min⁻¹ with ±0.005 in pitch accuracy.

Full-Width Roller-Feed Perforating

Selective lane or edge perforation that punches only programmed zones, creating alternating solid and perforated bands for ventilation, filtration, or decorative effects while maintaining panel strength.

Sectional / Side-Stagger Perforating

Integrated line that uncoils, perforates, roller-levels, and shears material to length—delivering flat, perforated blanks ready for downstream fabrication without intermediate handling.

Coil-to-Sheet Perforation

Sheet- or strip-fed press operation using single-hit, gang, or progressive dies to punch complex hole arrays or non-standard shapes not achievable with rotary perforation.

Custom Pattern Die Punching

Diamond’s integrated cutting, leveling, and forming cell combines CNC fiber-laser, turret punching, shear lines, 110-inch roller levelers, and 230-ton press brakes. The line processes coil or sheet up to 1⁄2-inch thick and 20 ft long, maintaining ±0.010-inch cut tolerance and ±0.020-inch bend accuracy while delivering flat, ready-to-assemble components in as little as one week.

Cutting is the primary material-removal operation in metal fabrication, producing net or near-net shapes from plate, sheet, bar, and structural profiles. It spans thermal, mechanical, and abrasive methods—including laser, plasma, oxy-fuel, water-jet, shearing, sawing, and abrasive-cutoff—each selected for its speed, kerf width, edge quality, and heat-affected zone characteristics. Cutting establishes dimensional references and critical edges for all downstream forming, welding, and finishing steps.

Cutting

Corrective leveling with 17–23 staggered work rolls and hydraulic backup flights, removing coil set and cross-bow to achieve flatness ≤0.003 in·ft⁻¹ for laser or stamping stock.

Precision Roller Leveling

Shearing involves cutting metal sheets or plates by applying a high-pressure tool on a metal surface, creating a straight cut.

Shearing

Press Brake Forming uses a press brake machine to bend and form sheets of metal with high precision, making it essential for detailed metalworking applications.

Press Brake Forming

CNC turret punching uses a rotating tool carousel and programmable X-Y sheet positioning to nibble, lance, form, or fully punch shapes in sheet metal up to 0.250 in thick. Ideal for medium-volume parts requiring multiple hole sizes, louvers, or emboss features without dedicated hard tooling.

Turret Punching

Computer-numerical-controlled (CNC) laser cutting concentrates a high-energy fiber or CO₂ laser beam—typically 1 kW – 20 kW—onto sheet, plate or tubing to melt, burn or vapor-cut metals, plastics and composites. Kerf widths average 0.008 – 0.012 in (0.20 – 0.30 mm) with positional repeatability of ±0.001 in (±0.025 mm). Dynamic focus, nitrogen assist gas and bevel-head options enable micro-features, weld-prep chamfers and near-burr-free edges while eliminating hard tooling and minimizing the heat-affected zone (HAZ).

Laser Cutting

Single-stroke or progressive-die blanking in presses ≥600 US tons, fully shearing part perimeters from coil or sheet to produce burr-free blanks for deep-draw and transfer operations.

High-Tonnage Blanking

Precision Cutting & Forming

Diamond’s multi-process welding department joins carbon steel, stainless, and aluminum fabrications—from thin-gauge perforated skins to ½-inch structural frames. Manual MIG/TIG stations handle prototypes and complex assemblies, while dual-arm robotic MIG cells run high-volume parts with ±0.020-inch positional accuracy. Integrated spot welders and fixtured assembly tables complete turnkey sub-assemblies that ship direct to the customer’s line.

Welding & Joining encompasses thermal-fusion and solid-state techniques that permanently unite metal (and some plastic) components. Processes include arc welding (MIG/GMAW, TIG/GTAW, Stick/SMAW, FCAW), resistance welding (spot, seam, projection), high-energy beam welding (laser, electron-beam), solid-state options (friction-stir, explosion, diffusion), and low-temperature joining such as brazing and soldering. Proper joint design, filler-metal selection, heat input control, and post-weld inspection are critical to achieving the required mechanical and metallurgical properties.

Welding & Joining

Multi-shift robotic operation with Poka-Yoke fixtures and automated QC.

Dedicated fixturing and robotic cells for sustained production.

Hand-welded proof-of-concept parts with full inspection records.

Cell-based manual or robotic welding for pilot or service volumes.

Gas-metal-arc welding using solid or metal-cored wire with inert/active shielding gas. Offers high deposition rate and ease of automation for steel, stainless and aluminium fabrication.

MIG (GMAW) Welding

Gas-tungsten-arc welding employing a non-consumable tungsten electrode for precision, low-spatter welds on thin or critical materials including stainless steel, aluminium and titanium.

TIG (GTAW) Welding

Automated MIG/TIG or resistance welding cells using multi-axis robots with seam tracking and adaptive weave for repeatable, high-volume joint quality.

Robotic Welding

Spot Welding fuses overlapping metal surfaces via resistive heat from an electric current, frequently used in automotive assembly.

Spot Welding

Welding & Assembly

Diamond offers a turnkey post-processing suite that deburrs, cleans, and finishes perforated or fabricated parts to end-use readiness. In-house Timesavers belt machines remove burrs on sheets up to 72 in wide, while multi-stage spray-wash systems degrease weldments before coating. Finishing options include architectural-grade powder coat, MIL-spec chromate conversion for aluminum, sulfuric anodizing to 0.001 in thickness, and electropolishing for stainless steel. Tight process controls ensure consistent color, gloss, and corrosion resistance across production lots.

Surface treatment & finishing encompasses chemical, mechanical and thermal operations—tumbling, vibratory deburr, abrasive blasting, electropolishing, anodizing, chromate conversion, hard-chrome or nickel plating, powder coating, wet painting and ceramic or PVD/CVD overlays—that modify a part’s surface for appearance, corrosion resistance, wear protection or adhesion. Processes routinely achieve ≤ 8 µin Ra finishes, controlled coating thickness from 0.0001 in to 0.010 in and salt-spray performance exceeding 1 000 h to ASTM B117.

Surface Treatment & Finishing

Conveyor powder line and batch anodize tanks scaled for high volumes.

Dedicated rack space and masking fixtures for repeat work.

Sample panels or first-article finish verification.

Small batches with color change flexibility.

Deburring is a critical post-processing operation that removes sharp edges and burrs from metal parts resulting from machining operations. It is essential for ensuring part functionality, safety during handling, and preparing surfaces for further finishing processes. Deburring can be performed using manual techniques, mechanical methods, or through thermal energy, and is applicable across a wide range of industries where smoothness of the part surface is required.

Deburring

The process of removing contaminants, such as dirt, oil, and grease, from industrial parts to ensure proper function and longevity.

Parts Cleaning

Anodizing is an electrochemical process that enhances the natural oxide layer on metal parts, primarily aluminum. It improves corrosion resistance, wear resistance, and surface hardness, and can also be used for color finishing. Anodizing is essential in industries like aerospace, automotive, and consumer electronics. The process includes Type II for decorative finishes and Type III for hard anodizing, providing a thicker, wear-resistant layer.

Anodizing

Chem Film, also known as Chromate Conversion Coating, is a chemical treatment for metals (such as aluminum) that enhances corrosion resistance and prepares the surface for further finishing. It is widely used in aerospace and automotive industries, particularly for parts where electrical conductivity is essential.

Chem Film (Chromate Conversion Coating)

Electropolishing is an electrochemical process used to polish, passivate, and deburr metal parts, removing a thin layer of material to achieve a smooth, bright surface. This is vital in medical, food, and aerospace industries where contaminant-free surfaces are critical.

Electropolishing

Powder Coating is a dry finishing process where a powder material is applied to a metal surface, then cured under heat to form a hard, protective layer. This coating is durable, corrosion-resistant, and available in many colors, making it popular in automotive, appliance, and consumer goods industries.

Powder Coating

Surface Finishing & Cleaning

Diamond’s engineering group functions as an extension of the customer’s design team—providing CAD/CAM programming, in-house tooling design, DFM reviews, and project engineering oversight. Leveraging a 4,000-pattern library and full tool-room machining, they turn concepts into production-ready models, produce new perforation dies in as little as five business days, and manage APQP documentation for automotive or regulated projects.

End-to-end engineering and design services including CAD/CAE modeling, finite-element analysis, tolerance stack-up, DFM/DFA feedback and fixture design. Teams leverage multi-CAD platforms and PLM integration to deliver manufacturable product designs optimized for cost, performance and assembly.

Engineering & Design Services

Design and analysis of jigs, nests and cutting tools using FEA and simulation to ensure repeatability and interchangeability.

Production Tooling & Fixture Design

Engineering service that creates optimized CNC turret-punch or laser programs, including nesting, tool sequencing, and simulation, to maximize material utilization and minimize cycle time.

CAD/CAM Pattern Programming

Design-for-manufacturability and design-for-assembly consulting evaluates product designs for optimal manufacturability, assembly cost reduction and quality control. Experts deliver actionable reports on feature simplification, material selection, draft angles and assembly gauge strategies to reduce cycle times and scrap rates.

DFM / DFA Consulting

Vendor Coordination & Supply-Chain Management orchestrates multi-tier suppliers—covering RFQ aggregation, PO release, expediting, quality surveillance, and logistics—to deliver complete assemblies or projects on time and within budget. The service provides a single point of contact that mitigates risk through supplier qualification, capacity planning, and real-time status reporting.

Vendor Coordination & Supply-Chain Management

Engineering & Design Support

Diamond’s logistics team engineers protective packaging, maintains more than five hundred stocked SKUs for 24- to 48-hour quick-ship, and manages blanket contracts with fixed pricing and JIT deliveries. Dedicated program managers integrate EDI, send advance-ship notices, and run dock-to-stock quality plans that keep delivered parts at a measured 98.7 percent on-time and 400 PPM or better defect performance.

Packaging / Kitting is a value-added service involving the sorting, assembly, and packaging of individual components into organized kits or finished sets. This service streamlines downstream operations such as final assembly, inventory management, and logistics by ensuring that all required items are grouped, labeled, and packed for efficient delivery and use. Typical use cases include service kits, BOM-based assembly packs, and retail-ready bundles.

Packaging / Kitting

Climate-controlled storage, inventory rotation and order fulfilment for finished parts with barcode or RFID traceability and real-time ERP integration.

Warehousing (Finished Goods)

Inventory Management & Logistics plans, stores, packages, and ships finished parts using JIT, Kanban, and blanket-order strategies to optimize customer supply chains and reduce total landed cost.

Inventory Management & Logistics

A certified quality-assurance program in which incoming parts bypass receiving inspection and move directly to production inventory. Requires pre-approved process controls, statistical sampling, and detailed certification packets from the supplier to ensure conformance before shipment.

Dock-to-Stock Quality

Provides perforating, leveling, shearing, or packaging on customer-supplied material; pricing covers labor and overhead while the customer retains material ownership and traceability.

Toll Processing (Labor-Only)

Supply-Chain Programs & Packaging

A global standard for quality management systems focusing on continuous improvement and customer satisfaction.

ISO 9001:2015

Diamond Manufacturing Company is North America’s largest perforator and value-added metal fabricator. Across six U.S. plants totaling 500,000 ft², the company runs 56 perforating presses (20–500 ton), 20 roller levelers, lasers, turret punches, press brakes, and welding cells. In-house engineers design tooling, optimize patterns, and support DFM. Certified to ISO 9001, ISO 14001, and IATF 16949, Diamond delivers flat, tight-tolerance perforated sheets, formed parts, and turnkey assemblies for automotive, aerospace, architecture, energy, HVAC, and heavy-equipment OEMs.

140 000-ft² flagship plant nestled in Pennsylvania’s industrial Wyoming Valley—less than 5 mi from the I-81/I-80 interchange, the Norfolk Southern intermodal yard, and Wilkes-Barre/Scranton International Airport—putting 40 % of U.S. manufacturers within a one-day truck haul. The site concentrates the network’s largest array of perforating presses plus laser-, turret-punch-, brake-, welding-, powder-coat-, and engineering cells. A 2023 expansion added dedicated inline perforating-and-leveling lanes to streamline high-volume East-Coast and Midwest programs while minimizing freight and lead-time risk.

Diamond Manufacturing Headquarters – Wyoming, PA

Full-service perforating and fabrication plant 60 mi from downtown Chicago on the I-94/Lake-Michigan freight corridor and minutes from the Port of Indiana–Burns Harbor rail-and-barge complex. The location anchors Diamond’s Great-Lakes reach—serving the automotive, heavy-equipment, and appliance belt—while offering Foreign-Trade-Zone advantages for export and duty deferral.

Diamond Manufacturing Midwest – Michigan City, IN

Historic Ferguson site on the I-95 Northeast corridor—15 min from Port of Providence deep-water terminals and within 1-hr drive of Boston’s aerospace, medical-device, and tech clusters. Specialises in complex engineered patterns and tight-tolerance perforations, drawing from a seasoned New England precision-manufacturing talent pool.

Ferguson Perforating – Providence, RI

Southern coil-perforation hub on the I-24 smart-manufacturing corridor midway between Nashville and Chattanooga—within 250 mi of nine major automotive assembly plants and benefiting from TVA low-cost energy. Enables just-in-time shipments to Southeast OEMs while sharing QMS and tooling with the Wisconsin flagship.

McKey Perforated Products – Manchester, TN

Western-Pennsylvania plant positioned at the crossroads of I-376, I-80, and the Ohio-River rail network—linking Pittsburgh’s advanced-materials hub to the automotive and energy markets of Ohio and West Virginia. Focuses on heavy-gauge precision perforation and fabricated assemblies, complementing the Providence engineering center while shortening transit for Midwest customers.

Ferguson Perforating – New Castle, PA

Coil-fed perforation centre 10 min off the I-94 Chicago–Milwaukee super-corridor and 15 mi from Port Milwaukee, giving next-day LTL coverage across the Upper Midwest. High-speed presses, slitters, and levellers support OEM coil programs for agricultural, HVAC, and appliance giants clustered in Wisconsin, Illinois, and Minnesota.

McKey Perforating – New Berlin, WI

NA’s leading perforated-metal specialist with six U.S. plants, ISO/IATF certifications & full fabrication.

Diamond Manufacturing

Perforated Metal & Value-Added Fabrication

Metal Perforation

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