Most major SIP manufacturers can produce custom panel dimensions — non-standard widths, non-standard lengths, and non-standard openings — though their capability, lead times, and minimum order requirements for custom configurations vary significantly.
Standard vs. custom production
Standard SIP panels are 4 feet wide and available in lengths of 8, 10, 12, and 16 feet (with some manufacturers producing up to 24-foot lengths for roof panels). Custom widths — 2-foot, 3-foot, or any non-4-foot dimension — require a dedicated production setup that adds cost and extends lead time. Custom lengths within the manufacturer’s production range are typically easier to accommodate than custom widths.
Custom window and door opening cuts — either as pre-cut panels from the factory or as additional cuts on standard panels — are available from most manufacturers as a standard service. Factory-cut openings are included in the panel order with dimensions from the approved plans. Field cutting of openings from full panels is also possible but produces more waste and adds field labor cost.
Manufacturers with strong custom capability
Permatherm and specialty manufacturers with smaller production volumes have more flexibility for custom configurations than high-volume residential manufacturers whose production is optimized for standard panel runs. For projects requiring significant custom panel dimensions — timber frame infill with non-modular bay dimensions, specialty commercial applications, or structures with unusual geometry — the manufacturer’s custom production capability is a selection criterion alongside delivered cost and lead time.
What custom production costs
Custom panel configurations typically cost 10 to 25 percent more than equivalent standard panels, reflecting the setup cost of non-standard production runs and any waste associated with cutting non-standard dimensions from standard production materials. For projects where custom dimensions reduce field waste and installation time, the custom panel premium is often cost-effective relative to the field cutting and waste of using standard panels for non-modular applications.
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