Etching Metal Meshes, Screens, Grids and Filters
- Holes as small as .004" (see conditions)
- Minimum hole size >= to 110% of metal thickness
- Minimum ligature between holes >= to metal thickness
Photochemical etching is an ideal process for metal grids, screens, meshes, filters, separators, microfilters, grilles, lighting diffusers and other perforated metal applications.
The photo etching process produces consistent, burr-free holes as small as .004” in .002” thick material. As a general rule, minimum hole size is 110% of the thickness of the material, e.g. on .010” material, the smallest hole would be .011.”
Unlike mechanical perforating methods such as punching, stamping or laser cutting, photochemical machining of metal leaves the material free of burrs and induced mechanical or thermal stress or deformation.
Applications range from heavy gauge metal effluent filtration to extremely fine thin-gauge filters and diaphragms for liquids and gasses in a variety of alloys including steel, copper, aluminum, nickel and molybdenum.
Metal meshes can be photo etched in a wide variety of alloys including steel, nickel, copper, brass, aluminum and more. Holes can be made in a variety of shapes and sizes at no additional cost in tooling.
Photo etched meshes, grids, filters and screens are used in many types of industrial, decorative and architectural applications. In many cases, chemical etching of metal meshes, grids, screens and filters provide better value and performance than woven or punched products.
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| Photonic transmission control screen | Space shuttle environmental system filter |
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| Detection filter | Beryllium copper mesh |
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| Filters for plasma deposition | |
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| 3/4" in-line fluid filter | Perforated diaphragm with half etched channels |
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| Ventilation screen | Battery grid |
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| Coarse grain fluid filter | |
Etching Metal Meshes, Screens, Grids and Filters Frequently Asked Questions
Q: What are the limitations for etched screens?
A: The minimum hole size needs to be, preferably, 120% of the metal thickness and the minimum ligature between holes is not less than the metal thickness and never less than .005 inches.
Q: What is the largest screen you can make?
A: Our equipment can process screens up to 24” x 60”
Q: What are the thinnest and thickest materials you can process?
A: .001 inches in most alloys and up to .080 inches in aluminum.
Q: How much do etched screens cost?
A: For common alloys (stainless, copper, brass, aluminum) between .010 and .020 thick, you can expect costs between .20 and .30 per square inch, assuming 120% minimum hole size.
Q: How much does tooling cost?
A: For screens up to 24” x 24”, generally, $265.00
Q: Do you have any standard screens?
A: No. Everything is made to customer specifications.
Q: Do the holes have to be round?
A: No. The holes can be virtually any shape and they don’t have to be the same shape. Any collection of shapes can be made. The caveat is that the minimum radius is equal to the material thickness and the 120% rule applies to the narrowest area of an opening.
Q: Can screens have solid borders?
A: Yes.
