Everything You Need To Know To Find The Best Expanded Metal Mesh

Expanded material can be produced thinner than any other open area materials in the industry, making it the best solution for lightweight applications. The unique “slit & stretch” expansion process produces zero scrap and can achieve open areas up to 95% with very small, accurate, openings.  In addition, the expansion process yields more material output than input, thus making it a very cost effective process.

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Perforated material is better suited for applications requiring less than 40% open area.  The process yields far more scrap than expanding because scrap is directly related to the amount of open area. The tooling is also more complex and costly to produce with higher rebuild costs making this process far more expensive.

Wire mesh and other woven products tend to be stronger than expanded materials but are limited on how thin they can be produced because of the over under aspect of the weaving process.  Openings are inconsistent due to moving strands making it a poor choice for applications that require controlled openings. Woven material also has a tendency to fray or unravel during secondary processing making it difficult to cut patterns or shapes.

Different specifications - Because different industries and applications have different requirements to meet, we work with you to create the best possible solution and won’t stop until you’re more than satisfied with the performance.

Quality - Not only does our team work with you to establish the perfect solution, but we create and refine the machinery with intense precision to produce a high quality, repeatable product and test our products to ensure they perform at the peak of performance.

Thickness - Our expanded material outperforms the competition because our in-house proprietary expansion equipment allows us to produce materials with thicknesses down to 25 micron with apertures down to 100 micron.

What is appropriate for the environment of the application?Some materials will need to prevent corrosion, others to disperse electrical currents, and some to screen and filter materials. Our team will work with yours to develop an application specific solutions to ensure top performance of our expanded materials in any environment.

Ten years ago, materials could be made as thin as 50 microns and as wide as 12 inches. Now, metals can be expanded down to 30 micron at 48 inches wide. Dexmet has even produced expanded materials down to thicknesses between 18 and 25 microns thin.

We shear and stretch foil and film gauge materials into consistent diamond shaped patterns, forming open area material with apertures down to 100 microns that can be made to be lighter-weight and thinner than the competition. The ability to control the tool geometry, feed rate, and depth of penetration into the material provides the ability for materials to be fine-tuned through infinite variables.

Long way of the diamond (LWD) – Measured from the center of one node to the center of the adjacent node, the LWD is always parallel to the width of the coil and corresponds with the diamond dimension.

Short way of the diamond (SWD) – Measured from the center of the node to the center of the node, the SWD is perpendicular to the width of the coil. For each fixed LWD dimension there is a SWD range.

Strand width – The amount of metal slit from the parent metal in forming the mesh. The strand thickness is directly proportional to the machine feed rate.

Measure one inch and count the number of meshes (or openings – between two nodes) along the SWD direction. We generally refer to MPI in the SWD direction and not the LWD direction. See Standard Product Range for the mean MPI count for each Mesh Designation.

This will let us know how to staff your project and prioritize it accordingly. 

This not only informs the type of material needed but enables us to alot time for appropriate testing.

When you have the application needs AND your company needs identified and ready to be discussed, you’ll ensure alignment between you and Dexmet right out of the gate and gain these benefits:

We work with you and your engineering/manufacturing team to determine the best expanded material solution for your application to ensure the best end result every time. We aim to exceed expectations.

Next we identify which tool should be used for this project, or create one according to the parameters. The shape, form, and number of openings are dictated by the particular tool die geometry used.

Then we start the “slit and stretch” expansion process. A precision die shears the material as it penetrates the solid foil and stretches the material to the geometry of the tool in a single operation. The tool lifts and indexes over the distance dictated by the LWD and penetrates the material again. Each stroke of the machine produces half a diamond.

Not all tests are done on every material produced– only the tests for the particular needs of that application and according to industry requirements.

Your Dexmet team will guide you through the necessary tests and results planned for your products.

Our testing plan, done before the application goes into production, ensures a quality expanded material product is replicated time and time again.

Sample materials are generated based on the criteria provide.  Once tested, we’ll follow up to make sure it exceeds your expectations. If not, we’ll continue to work with you and provide more samples until you are completely satisfied with the results.

Expanded materials are not always right solution for every application, but our unique manufacturing process combined with an expert team of engineers will help ensure that every solution we provide will allow you to be both on-time and on-budget, while receiving a top Dexmet product.

The Mesh Company are broadening our range ever further in . One material that we are delighted to now offer is expanded metal mesh (EXP). We will be launching new options across the year, and we have written this handy guide to hopefully answer any question that you may have.

Expanded metal is also known as expanded sheet metal, or just expanded metal. It a type of sheet metal that has been cut and stretched to create a diamond-shaped pattern. This process increases the surface area of the metal, making it more durable and versatile. Expanded metal mesh is commonly used for architectural and industrial applications, such as building facades, security fencing, and machinery guards. It is available in a wide range of materials, including steel, aluminium, and stainless steel, and can be customized to meet specific structural, aesthetic, or functional requirements.

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Perforated metal sheet may also be of interest as it is a similar product type. It is totally flat however, which may suit some applications better.

Yes. Expanded metal ceiling tile can be used in a variety of applications, including commercial and industrial buildings, as well as in residential settings. They are suitable for high traffic areas, such as airports, shopping centres, and other public spaces. These tiles are easy to install and can be suspended from a ceiling grid system. They are also lightweight, which makes them easy to handle and install. Additionally, Expanded metal replacement ceiling tiles are fireproof, soundproof and heat insulation. They also offer high ventilation and light transmission, making them an energy-efficient solution for lighting and HVAC systems.

Expanded metal mesh can be used as a reinforcing material for rendering, also known as a “scratch coat”, which is the first layer applied to a surface before the final render is applied. The expanded metal mesh is typically embedded in the wet rendering material and provides additional strength and stability to the surface, preventing cracking and other issues. It also helps to bridge any cracks or holes that may exist in the surface, providing a smooth and even surface for the final render.

It is used in the external insulation and finish systems (EIFS) in the construction industry as a reinforcement for the insulation layer. It is applied to the insulation layer which is then covered with a finish coat, this helps to increase the strength and durability of the insulation, preventing cracking and other issues.

Additionally, expanded metal mesh is also used in the construction of stucco walls, which is a traditional form of wall finish made of cement, sand, and water. The expanded metal mesh is embedded in the wet stucco mixture and helps to reinforce the wall and prevent cracking.

It can be cut using a variety of tools, such as tin snips, bolt cutters, or power saws. Tin snips are a manual tool that work well for cutting small pieces of expanded metal, while bolt cutters can handle larger pieces. Power saws, such as a metal-cutting band saw or a plasma cutter, can also be used to cut expanded metal, but they require a high level of skill and experience to operate safely.

It all depends on the thickness of the product. There are cutting guides on every product page depending on the material itself. We also offer a free cutting service if you require a bespoke size.

Yes, it is possible to weld expanded metal, but it can be more difficult than welding solid sheet metal due to the open structure of the material.

When welding expanded metal, it is important to use the correct type of welding process and filler metal. The most common welding process used for expanded metal is Gas Tungsten Arc Welding (GTAW), also known as Tungsten Inert Gas (TIG) welding, which is a precise and clean process that allows for control of the welding heat.

Another option is Gas Metal Arc Welding (GMAW) also known as Metal Inert Gas (MIG) welding, which is a faster process that also produces a clean weld.

To ensure a strong weld, it is also important to use a filler metal that is compatible with the expanded metal and the base metal. The base metal should be cleaned thoroughly before welding to remove any dirt, grease, or oil to ensure a good weld.

In general, welding expanded metal is a challenging task that requires skill and experience. It is always recommended to consult with a professional welder and make sure to follow safety guidelines when welding.

Yes, you can paint expanded metal. However, the open structure of the material can make it more difficult to paint than solid sheet metal. Also, some metals do not take paint. Plain steel is the best for painting.

Before painting expanded metal, it is important to clean it thoroughly to remove any dirt, grease, or oil. This will ensure that the paint adheres properly to the surface. A wire brush or sandpaper can be used to remove any loose rust or debris.

It’s a good idea to use a high-quality, rust-inhibiting primer before applying the final paint coat. This will help to prevent rust and protect the metal from the elements.

When applying the paint, it’s important to use a brush or roller with synthetic bristles or foam, as natural-bristle brushes can leave brush marks on the surface of the expanded metal.

It’s also important to use paint that is suitable for metal surfaces and to apply it in thin, even coats. Avoid applying too much paint in one area, as this can cause drips and runs.

It’s highly recommended to use a paint with a good quality and with the ability to withstand the elements, like a epoxy paint, or a polyurethane paint.

It’s also important to follow safety guidelines when painting, as some paints may contain harmful chemicals.

Yes, it is possible to bend expanded metal, but it can be more difficult than bending solid sheet metal due to the open structure of the material.

The process of bending expanded metal typically involves using a brake press or a press brake. This is a machine that uses a punch and die to bend the metal to a specific angle. The punch pushes the metal against the die, which shapes the metal as it is bent.

It’s important to note that the open structure of the expanded metal can make it more prone to tearing or cracking. To avoid this, the metal should be bent gradually and at a slow speed, and the punch and die should be adjusted to the appropriate size and shape for the metal being bent.

Also, it’s important to use a lubricant to reduce friction and heat during the bending process to avoid cracking.

It’s highly recommended that the metal should be bent at the manufacturer or by a professional metal bender with experience working with expanded metal. As the process can be complex and requires specialized equipment, and knowledge of the metal properties to avoid any damage.

Bending expanded metal can be challenging and it’s important to follow safety guidelines when working with metal and equipment.