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I would like to have some advice of case modding, instead of using hole saw to cut a hole and get a fan grill on my pc case, is it possible to punch the grill directly on the case itself? FYI the thickness of the case is around 0.7mm +/- 0.1mm.

Dont laugh at my paint skills lol, i suck at drawing
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It could turn out ugly if things go wrong...

 

I'd rather make a big hole and add a grill and dust filter. Less resistance to air flow that way.

i woudlnt even use a dust filter if sound levels are important or you clean the system once a month.

jsut find a somewhat more fine than the usual ones, maybe like two wires per inch?

but thats just me.

 

and yeah, cutting one big hole and adding the grill will be heaps easier than many tiny holes.

 

by the way thanks, for asking thsi question, it wacttually reminded me to add this kidna stuff inot consideration for the case i plan on having 3d-printed sometime in the future. ^~^

Watch out for each other. Love everyone and forgive everyone, including yourself. Forgive your anger, forgive your guilt. Your shame. Your sadness. Embrace and open up your love, your joy, your truth, and most especially your heart. 
-Jim Hensen

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I agree with the above posts... It could get messy really easily. I'm not sure how you would go about getting hex shaped holes... but maybe you could place a piece of flat scrap wood behind the panel and clamp down a frame of wood on the other side... Use a center punch to help you align the drill holes... Make sense?

 

best of luck!!!

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