Metal mesh filters and screens produced by photochemical etching are high-precision flat metal filter components. Unlike woven wire mesh or punched perforated sheets, the holes are chemically etched out from solid metal foil. The aperture size, shape, pitch and open area can be fully customized. The mesh remains completely flat, with consistent hole geometry across the whole panel. Available materials include 304 / 316L stainless steel, nickel, titanium, copper, brass and kovar. Typical thickness ranges from 0.02 mm to 1.5 mm. Minimum micro holes can reach 0.03 mm, supporting round, square, rectangular slot and irregular custom patterns. Widely used for liquid filtration, gas separation, particle screening, atomization, shielding and fluid distribution.

Step-by-Step Etching Workflow for Metal Mesh Filter & Screens

1. DFM & Artwork OptimizationEngineers review vector drawings, calculate open area, aperture pitch and undercut compensation. We adjust hole layout to guarantee uniform flow rate and structural strength, avoid fragile thin bars between micro holes.
2. Surface Pre-treatmentMetal sheets go through alkaline degreasing, rinsing and oxide removal. Oil and fingerprints are fully cleaned to ensure stable photoresist adhesion and consistent etching depth.
3. Dry Film LaminationUV-sensitive dry film photoresist is laminated on both sides of the metal sheet under controlled heat and pressure.
4. UV Exposure & DevelopmentUV light transfers the mesh pattern onto photoresist. The developer washes away resist on areas for holes, exposing bare metal to be etched; protected areas remain as the mesh frame and ribs.
5. Chemical Etching (Core Process)Custom etchant selectively dissolves the exposed metal to form through holes. Double-sided etching ensures symmetric, smooth hole walls. No mechanical impact, no material deformation. Tapered holes can be customized for better fluid flow.
6. Resist Stripping & Multi-stage CleaningStrip photoresist mask, followed by DI water rinsing to remove residual etching chemicals.
7. Post-processing OptionsAvailable secondary treatments: passivation, electroplating (nickel, gold), polishing, welding, forming into cylindrical filter cartridges, bonding with support frames.
8. Dimensional Inspection & PackagingInspect aperture size, pitch, thickness, open area and edge quality. Use microscope and coordinate measuring machine for micro-hole verification before packaging.

Core Advantages of Etched Metal Mesh Filter & Screens

1. Uniform & precise micro aperturesHole dimension maintains excellent consistency across the whole mesh sheet. Hole shape and pitch can be freely designed, not limited to woven mesh weave structure.
2. Burr-free & stress-freeNo mechanical stamping or cutting force. Zero burrs, no residual stress, flat mesh surface, no hole blockage from micro burrs.
3. High structural stabilityNo wire crossover or loose wires compared to woven mesh. Mesh structure will not shift or deform under fluid pressure.
4. Flexible customisation, no hard tooling costOnly digital artwork required. Fast prototype turnaround, easy pattern modification, suitable from small sampling to mass production.
5. Wide material selectionStainless steel, nickel, titanium, copper and alloy options for corrosion resistance, high temperature, medical and food-grade environments.
6. Controllable open areaAccurately design open area to match target flow rate and filtration efficiency.

Typical Applications

• Medical industry: disposable filter screens, diagnostic device micro filters, drug delivery atomization mesh
• Automotive: engine oil filter, fuel filter, fluid separation mesh, coffee filter mesh
• Food & beverage: food-grade liquid filtration, beverage purification screens
• Semiconductor & electronics: gas filtration, EMI shielding mesh, inkjet print screens
• Aerospace & new energy: hydrogen fuel cell flow field mesh, battery particle separation
• General industry: water treatment, chemical filtration, laboratory test sieves, particle classification screens

Design Limitations & Notes

Etching is isotropic, side undercut must be considered during DFM. Minimum hole size is generally limited by material thickness, usually the smallest hole ≈ material thickness. Very large open area may weaken mesh mechanical strength, support ribs are required. If ultra-large mesh area is needed, combining etched mesh with welded support frame is recommended.