In one embodiment of the present disclosure, a method of manufacturing perforated metal honeycomb material includes: printing a roll of metal foil with adhesive; laser perforating the roll of metal foil to provide a plurality of holes in the metal foil; sheeting the printed and perforated roll of metal foil into a plurality of stacked sheets; and laminating the sheets of metal foil into a honeycomb before expansion block (HOBE). In another embodiment of the present disclosure, a perforated metal honeycomb structure includes a metal honeycomb structure having a plurality of laser-drilled holes wherein at least some of the plurality of holes are non-uniform in size, shape, and/or spacing between holes.