This article will take an in-depth look at metal mesh.
The article will bring more detail on topics such as:
In this segment, we delve into the concept of metal mesh, exploring its creation process and essential design considerations.
"Wire mesh" commonly pertains to structures constituted from multiple metallic wires that are connected using various techniques, forming either flat or three-dimensional frameworks. This versatile material is widely used in transportation, fencing, display setups, and protective barriers, serving significant roles across both industrial applications and everyday use.
Sheets of metal mesh are fabricated from an assortment of materials such as stainless steel, galvanized steel, plain carbon steel, aluminum, copper, bronze, brass, among other specialized metals. These materials are processed into wires of differing gauges, which are then woven or interlinked to produce uniform parallel rows and intersecting columns.
Also known as wire fabric, wire cloth, or hardware mesh, wire mesh is manufactured by weaving wire on machinery designed for industrial looms, creating square or rectangular gaps between each strand. In the case of welded wire mesh or cloth, the intersecting wires are fused together at junctions using electric welders.
Iron-derived steel has unique and beneficial attributes. Notably, stainless steel is completely rust-proof and incredibly durable, making it an optimal choice for various industry applications. Steel wires are particularly ideal for creating wire mesh and similar products due to their notable ductility, strength, and flexibility.
Wire mesh is among the antiquities in steel production, with its utility evident over thousands of years. As global economies expand, steel wire mesh sees varied new uses such as fencing, barricades, safety covers for machines, cages, grills, sifters, and shelving solutions.
Iron welded wire mesh is indispensable in concrete reinforcement. Companies generating steel wires supply them to secondary producers who transform them into mesh using weaving or welding techniques.
Important considerations include:
Recognizing temperature thresholds is critical when deploying heat-resistant wire mesh in high-temperature settings. Since any ductile metal or alloy can be employed for woven wire mesh, choosing the right material for each task is essential. High-temperature capacities include stainless steel grade 304 (1500°F or 815.5°C); Inconel (1800°F or 982°C); nickel (2700°F or 1482°C); and tungsten (5000°F or 2760°C).
While many wire cloth variants can corrode, materials like titanium and certain specialized alloys such as Hastelloy, Inconel, and Nichrome offer enhanced protection against corrosive conditions.
Viscosity is a vital factor in water treatment, oil processing, and chemical filtration. Efficient filtering is noted with less dense fluids. For optimal results with highly viscous fluids, the appropriate mesh type and size must be chosen. Note that viscosity often shifts with temperature changes.
The size of particles is a significant criterion when deciding on wire mesh. Select mesh count, aperture size, and wire thickness according to the particle size intended for retention. Use test sieves for achieving specific particulate measurement.
As substances pass through a filter, pressure decreases and contaminants are eliminated. The selected filter media has a significant impact on this pressure drop rate. Upon reaching a certain drop point, filter replacement is necessary. Aligning wire mesh selections with your pressure drop requirements aids in cost reduction and fewer contamination incidents.
Viscosity, pressure drop, and flow rate are interlinked. Choose the appropriate mesh aligning with specific flow rate needs while considering the mesh's open area percentage.
The type of pollutants encountered affects decisions on material, wire diameter, mesh density, tolerance levels, aperture size, and wire weave style.
Mesh settings may need adjustments based on usage. In production, wire mesh baskets and sieves assess and measure specific gravity of filtered substances. These products, usually brass or stainless steel, should be selected based on specific gravity testing requirements.
Various types of metal mesh include:
Expanded wire mesh, also known as expanded metal mesh or expanded sheet metal, is created by feeding metal sheets into an expanding machine, which simultaneously cuts and stretches the sheets to form a patterned mesh. This manufacturing process results in mesh panels with uniformly shaped diamond or hexagonal holes, providing a strong, robust, and consistent structure ideal for a variety of industrial and architectural uses. The final expanded wire mesh product is known for being heavy-duty, durable, and versatile in applications.
Expanded wire mesh is available in different forms and metals, such as carbon steel, stainless steel, and aluminum. These meshes are easy to weld, corrosion-resistant, and feature a long service life. Compared to perforated metals, expanded mesh provides superior airflow and ventilation, making it especially suitable for applications where cooling or thermal regulation is important. Thanks to its affordability, lightweight design, high strength-to-weight ratio, and minimal waste during manufacturing, expanded metal mesh is a popular choice for security fencing, walkways, machine guards, grating, screens, and more.
Woven wire mesh, sometimes referred to as wire cloth or woven wire fabric, features a precise pattern of intersecting metal wires created by fabric-like weaving. Typically, robust wire sheets are formed by interlacing wires over and under perpendicular wires, a method known as Plain Weave Mesh. For applications requiring greater flexibility, a Twill Weave pattern is available, where wires cross over two parallel wires, then under the next pair, resulting in a more pliable and drapable sheet.
Manufacturing woven wire mesh involves feeding wires into automated loom-like devices that weave a straight wire according to the desired wire diameter and opening size. After each layer, wires are woven through the pattern until the mesh reaches the specified length and width, then trimmed to finished size.
Woven wire mesh is available in various mesh counts, wire gauges, and opening sizes, serving widely in filtration, sieving, screening, and separation applications across industries such as mining, food processing, chemical processing, and pharmaceuticals. Its customizable nature, high strength, and excellent dimensional stability make it a staple in both industrial and decorative projects.
Welded wire mesh, also called welded mesh panels or welded wire fabric, is created using advanced welding equipment to join steel wires at precise intersections. This process forms a strong grid pattern where horizontal and vertical wires meet at 90-degree angles.
First, a set of parallel stainless steel, galvanized steel, or carbon steel wires is fed into the machine, followed by perpendicular wires. The machine uses electrical resistance welding to fix each intersection securely, ensuring high strength and uniformity. The process is repeated with additional wires until the roll or panel reaches specified dimensions, then the mesh is cut or rolled as required.
Mechanical Positioning � Cut wires are arranged horizontally across wires drawn from spools, forming right angles. Once properly aligned, the automated welding process starts—producing mesh with consistent dimensions and quality.
Final Steps � After welding, welded wire mesh is rolled or cut into sheets to create mesh panels. These mesh sheets are then stacked or further processed for use in fencing, concrete reinforcement, animal cages, safety guards, infill panels, and more. Compared to woven wire mesh, welded mesh is heavier, has greater structural integrity, and is available in a wide range of wire gauges and mesh sizes to suit commercial and industrial purposes.
To create a more robust protective barrier, a vinyl or PVC coating is applied over welded or woven wire mesh. This vinyl-coated wire mesh, also known as PVC coated wire mesh, enhances resistance to impacts, scratches, abrasions, and harsh weather conditions while maintaining flexibility over a broad temperature range.
Often referred to as plastic mesh due to its vinyl coating, this wire mesh is both durable and attractive, with excellent resistance to rust, corrosion, and UV radiation. The vinyl layer adds a smooth finish and is available in various colors for commercial, residential, and agricultural fencing, garden trellises, animal enclosures, and more. The coating also protects the base metal wire from environmental factors such as moisture and chemicals, extending the lifespan of the mesh even in outdoor and marine environments.
Galvanized wire mesh is produced from carbon steel wire or raw steel wire that is protected with a zinc coating through hot-dip galvanizing or electro-galvanizing. This zinc barrier provides exceptional corrosion resistance and rust protection, making galvanized mesh suitable for outdoor and harsh environments.
Galvanized wire mesh can be manufactured as woven or welded mesh—galvanized after weaving or welding to ensure maximum durability. This type of mesh is widely used in industrial and commercial settings, including window guards, infill panels, greenhouse and garden fencing, agricultural livestock fencing, perimeter and construction fencing, and security barriers. Its affordability and low maintenance requirements make galvanized mesh one of the most popular wire mesh varieties for long-term outdoor use, especially where exposure to moisture or chemicals is likely.
Stainless steel wire mesh stands out for its superior corrosion resistance, strength, and longevity, and incorporates all the advantages of stainless steel alloys. Unlike standard steel, stainless steel resists rust even when exposed to moisture or harsh chemicals, thanks to the addition of chromium and other alloying elements. This ensures lasting protection against oxidation and staining.
Wire mesh made from stainless steel is favored for high-performance industrial applications where durability is crucial, such as in oil and gas processing, marine environments, food and beverage production, chemical processing, water treatment, and pharmaceutical filtration. The mesh can be fabricated using welded or woven construction, depending on specific project requirements.
Stainless steel wire mesh is available in key grades like 304, 316, and 316L, offering a range of mesh opening sizes, wire diameters, and surface finishes to suit fine filtration, heavy-duty screening, decorative panels, or architectural applications. Grade 316 stainless offers outstanding resistance to acids, saltwater, seawater, and chloride environments, making it essential for coastal or marine use. While grade 304 stainless is more affordable and easy to form, 316 provides higher corrosion protection. Common uses include safety screens, machine guards, fencing, sieves, infill panels, basket strainers, and architectural cladding.
Wire netting, sometimes called hexagonal wire mesh, chicken wire, or wire fencing net, is a versatile mesh structure characterized by its woven, usually hexagonal or rectangular, pattern. Wire netting is commonly used for perimeter fencing, aviaries, garden enclosures, and agricultural barriers to protect crops, livestock, and property. In forestry and agriculture, hexagonal netting helps fence woodland areas and prevents animal intrusion, while rectangular netting is used for general property enclosures.
Wire netting also serves critical roles in erosion control, slope reinforcement, avalanche protection, and rockfall barriers due to its ability to absorb and contain loose debris. Specialized types, such as circular braids, are used for shielding cables from electromagnetic interference and reinforcing hoses or industrial tubing. Durable, flexible, and rust-resistant, wire netting is a cost-effective solution for both residential and commercial security fencing, landscaping, and infrastructure projects.
Choosing the Right Metal Mesh for Your Application
Selecting the optimal metal mesh type—whether expanded metal, welded mesh panels, woven wire cloth, galvanized mesh, stainless steel mesh, or vinyl-coated fencing—depends largely on your specific project’s requirements, desired strength, exposure to weather, security level, and aesthetic preferences. By understanding the differences between these mesh types, end-users can make informed decisions for mesh fencing systems, filtration and separation equipment, architectural screens, and industrial safety barriers. To ensure maximum performance, always consider critical factors such as mesh opening size, wire gauge, coating or finish, and compliance with relevant industry standards and specifications.
This chapter will cover the materials used to make metal mesh and the various mesh patterns.
Wire, the main element of wire mesh, is made from different ferrous and non-ferrous metals. It comes in various gauges, which measure the wire's thickness. A lower gauge number denotes a thicker wire, while a higher gauge number indicates a thinner wire.
The wire gauge is consistent for both shute (weft) and warp wires in plain and crimped wire mesh. However, for Dutch weave wire mesh, the weft and warp wires have different gauges. Stranded wire mesh is composed of bundles made from very thin gauge wires twisted together.
The type and application of wire mesh are influenced by both the metals used and the wire gauge. Wire for mesh is produced by drawing raw metal through a die or draw plate. Besides cylindrical wires, wire mesh can also be made using rectangular, square, and hexagonal wires.
Steel, an alloy of iron and carbon, can adopt either a body-centered cubic or face-centered cubic crystalline structure depending on the temperature. The unique properties of steel and cast iron arise from the interaction between the iron allotropes and the primary carbon alloying element.
Elongation, or ductility, refers to a material's ability to be stretched or compressed without breaking. It is measured as a percentage of the original length and falls between tensile and yield strength. This property allows steel to be drawn into wires, which are then used to create metal mesh.
Copper wire mesh is highly valued for its excellent thermal and electrical conductivity, as well as its flexibility and malleability. It is commonly used in electrical applications and Faraday cages to shield against radio frequency interference. Like aluminum, which is seldom used in its pure form, copper is usually alloyed to enhance its natural properties.
Exposure to salt, moisture, and sunlight causes copper to change color from salmon-red to brownish-gray and eventually to blue-green or gray-green. To prevent this discoloration, copper wire mesh is treated with coatings and chemicals that either slow down or control the oxidation process.
Bronze is an alloy composed of 90% copper and 10% zinc. It retains many of copper's properties, such as malleability, ductility, and toughness. Compared to copper, bronze is tougher and less flexible, and it offers better corrosion resistance than brass. It is commonly used in industrial applications for filtration and architectural purposes.
Wire mesh is commonly made from the alloys and metals previously mentioned. In addition, specialized wire meshes can be crafted from materials like titanium, Hastelloy, Monel 400, nichrome, Inconel, and tungsten. Essentially, wire mesh can be produced from any ferrous or non-ferrous metal that can be drawn into wire.
Aluminum is inexpensive, lightweight, malleable, flexible, and resistant to corrosion. It is the most often used non-ferrous metal for making wire mesh; aluminum grade 1000, or pure aluminum, is rarely used to make aluminum wire mesh. To boost aluminum's strength and enhance some of its other features, most aluminum is alloyed with other metals like copper, magnesium, zinc, or silicon in certain amounts. The three alloys 1350, 5056, and 6061 are used most frequently to make aluminum wire mesh.
Brass, an alloy of copper and zinc, is used in wire mesh production in forms such as 270 yellow brass and 260 high brass. 270 yellow brass contains 65% copper and 35% zinc, while 260 high brass is made up of 70% copper and 30% zinc. Brass wire mesh is known for its high tensile strength, excellent abrasion resistance, and increased toughness due to the higher zinc content. Its distinctive yellow color makes industrial-grade brass wire mesh a popular choice for decorative and architectural applications.
The various patterns for metal mesh include:
The twill weave pattern is ideal for weaving thicker and larger diameter wires. In this pattern, the warp wires alternate over and under two weft wires, or vice versa. This method involves reversing the warp wire at the intersections, resulting in a rigid, strong, and stable wire mesh. As the pattern develops, it creates a staggered effect that appears as parallel diagonal lines.
Wire mesh with a twill weave is effective in filtering small particles and supporting heavier loads. It is commonly used in the production of filters, food colanders, chemical screens, and mosquito nets. Stainless steel grades 304 and 316, known for their resistance to acids and durability, are frequently employed in filtration applications.
A crimping mesh machine is used to produce crimped wire mesh with square or rectangular patterns. The process involves compressing the warp wires so they wrap over the weft wires, and vice versa. This crimping action bends the wires, causing them to interlock and wrap around each other.
Pre-crimped weaves involve crimping the wire before weaving, adding small folds or ridges to enhance the mesh's rigidity and strength. This process helps keep the weft and warp wires securely in place and prevents them from shifting.
The pre-crimping technique secures the weave at the intersections of the weft and warp wires by utilizing the grooves created during crimping. This results in a final weave that is stronger and more stable, similar to the effects of pre-crimping.
In the inter-crimp method, both weft and warp wires are subjected to an additional crimp between their intersections. This technique employs fine wire with broad apertures, ensuring that the wires are securely locked together and providing increased rigidity.
Non-crimped wire features a basic over-under weave of weft and warp wires, resulting in a wire mesh with a smooth and consistent surface. This type of mesh, known as plain weave, typically has a higher mesh count. Plain weave is one of the most commonly used wire mesh types, suitable for patterns with mesh sizes of 3 x 3 or smaller. It is often used for screening applications, including window screens and screen doors.
The flat top weave creates a robust wire mesh with a smooth, flat surface by using crimped weft wires and non-crimped warp wires. This design eliminates protruding wires, enhancing its durability and extending its abrasive life. With its low flow resistance, flat top weave wire mesh is ideal for architectural and structural applications that require a smooth finish. Common applications include vibrating screens.
Dutch weave wire mesh stands out from twill and plain weave mesh due to its unique construction. In Dutch weave, the weft wires are finer and have smaller diameters compared to the coarser warp wires, which enhances tensile strength. The finer weft wires improve filtering efficiency by creating smaller openings. Dutch weave wire mesh is often chosen for filtration applications because of its strength and precision. Both plain and twill Dutch weaving techniques offer distinct advantages tailored to specific application needs.
Plain Dutch weave wire mesh features a combination of a plain wire weave with the Dutch weave technique. In this mesh, the finer weft wire passes over and under the coarser warp wire, and vice versa. The main advantages of plain Dutch weave wire mesh include its mechanical stability, smaller openings, and exceptional tensile strength.
Wire mesh with a twill Dutch weave pattern merges a traditional twill weave with the Dutch weave technique. In this pattern, the finer weft wire alternates over and under two warp wires, creating a delicate mesh, while the coarser warp wires form a more robust mesh. The twill Dutch weave is preferred for its ability to support heavier loads and provide finer apertures compared to a standard twill weave, making it ideal for filtering applications.
Reverse Dutch woven wire mesh is similar to plain Dutch woven wire mesh but with the warp and weft wires switched. In this pattern, the warp wires are more robust as they are closely spaced and woven tightly with heavier weft wires. This configuration provides increased mechanical strength and is suitable for applications requiring acoustic properties, high durability, and efficient filtration.
Wire mesh edges can be classified into two types: raw and selvage. When wire mesh is woven, the weft wires form an edge along the roll's length to prevent unraveling. In a raw edge, these weft wires remain exposed at the mesh's edge.
Selvage edge wire mesh features a finished border that enhances the mesh's stability and ensures safety for those handling it. One common method of creating a selvage edge involves looping the wires along the mesh's edge.
This chapter will explore the advantages and uses of metal mesh.
Two- or three-dimensional structures made of two or more metallic wires joined by a number of methods are called "wire meshes." Wire mesh items are frequently used for carrying, displaying, fencing, and armoring in various environments. Thus, wire mesh is an essential part of both industry and everyday life.
Stainless steel, galvanized steel, plain carbon steel, aluminum, copper, bronze, brass, and other specialty metals are among the substances used to make metal mesh sheets. To create parallel rows and crossing columns that are roughly similar in size, wires of various thicknesses are braided, entangled, or connected together.
Before deciding on an application, it is vital to understand the metal mesh type and pattern, including the type of wire.
Wire mesh is fabricated by the intertwining, weaving, or welding of wires of various thicknesses to create proportionally equal parallel rows and intersecting columns. Also known as wire fabric, wire cloth, or...
Hardware cloth is a woven mesh made by interlacing various sizes of wire to form a metal fabric that can be used for animal cages, fence material, strainers, and filtering screens. The differences between the various types of hardware cloth...
Welded wire mesh is a series of wires that are welded where the individual wires cross. The openings of the mesh varies depending on the type of wire used and the function of the mesh. Regardless of size and wire, welded wire mesh is permanent and...
Wire cloth is a woven (or nonwoven) sheet or web material with a series of openings across the surface. Wire cloth is also known as: Metal Fabric or Metal Cloth; Wire Mesh, Metal Mesh, or Alloy Mesh...
Expanded metal is a sheet metal mesh. It is made by stretching a slitted sheet of malleable metal. The orientation of the slits is perpendicular to the direction of the stretch. The result of such stretching is an array of holes on the slits - to give a mesh form...
Perforated aluminum consists of an aluminum sheet which has been manually or mechanically pierced or punched using CNC (computerized numerical control) technology in order to produce shapes and patterns of various sizes...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
A perforated metal is a piece of sheet metal that has been stamped, fabricated, or punched to create a pattern of holes, slots, and various aesthetic shapes. A wide range of metals are used in the perforating metal process, which include steel, aluminum, stainless steel, copper, and titanium...
Perforated stainless steel is cut, punched, or stamped to produce a precise pattern of holes or apertures. It is used for functional reasons, such as filtration or ventilation, and aesthetic ones, such as architectural accents...
Perforated metals are sheets of metal that have had decorative shapes, and holes punched or stamped into their surface for practical or aesthetic purposes. The perforation of metal sheets takes several forms and includes a variety of geometrical patterns and designs...
Wire baskets are made from a series of wires that are woven together or welded to form a shape of a basket. They can also be defined as containers that are made by use of an openwork pattern of metal...
Wire shaping is a complex method that encompasses a wide range of dimensions, forms, and textures. The technique of creating a usable product by wire bending and shaping is known as custom wire forms...
Wire forming is a method for applying force to change the contour of wire by bending, swaging, piercing, chamfering, shearing, or other techniques. The various techniques for wire forming can produce any type of shape, form, or configuration...
A wire handle is attached to a bucket, pail, or other type of container to make it easy to lift the container and transport it. They are made of durable and sturdy metals capable of lifting several pounds...
A wire rack is a level wire form utilized to stock and exhibit a number of products, usually retail. The bottom surface on which such goods are stored is made of several latticed or interlaced metal strands...