Overview

A filter mesh etching service builds filtration performance into the metal itself. Round discs, washer-shaped screens and custom outlines are cut from solid sheet by photochemical machining: resist is exposed through aperture artwork and the open field is dissolved away, leaving a flat, one-piece filter disc whose holes are identical from edge to edge. A filter mesh etching service therefore controls the two variables that decide how a filter behaves — aperture size and open area — directly from the drawing, in stock from 0.05 mm to 1.0 mm of stainless steel 304/316L, nickel 200, titanium Grade 2 and copper C11000.

That control matters in fuel, air and fluid systems. A fuel inlet disc needs fine apertures with limited open area to hold back particles without collapsing under differential pressure; an air intake screen wants high open area with a coarser aperture to keep restriction low. Etched discs deliver both without woven fibres shedding into the line, and because the outline, the aperture field and any mounting holes are cut in the same operation, one part replaces an assembly of mesh plus ring. Discs come off the line flat and burr-free, ready for passivation, electropolishing or forming into cups and domes.

Parameter Window

• Available Materials: stainless steel 304/316L, nickel 200, titanium Grade 2, copper C11000
• Material Thickness Range: 0.05–1.0 mm
• Tolerance: aperture ±0.01 mm or ±5% of aperture size; disc outline ±0.05 mm; flatness 0.1 mm per 100 mm
• Minimum Feature: 0.03 mm aperture on 0.03 mm foil; 0.05 mm aperture on 0.05 mm stock; outer land width from 0.5 mm
• Surface Options: passivation, electropolishing, cup and dome forming, flanged edges, clean degreasing, interleaved packaging
• Compliance: ISO 9001 process control, RoHS/REACH material traceability

Manufacturing Process / Workflow (8 Steps)

1. Filtration Spec Review — Convert the target micron rating, flow and differential pressure into aperture size, open area and disc thickness.
2. Material Selection — Match alloy to the media: 316L for water and mild chemicals, nickel for heat and conductivity, titanium for aggressive fluids, copper for fuel-compatible assemblies.
3. Cleaning & Lamination — Degrease and laminate dry film resist so the fine aperture field etches without pinholes or residue.
4. UV Exposure — Expose aperture artwork and outline together, registered so the mesh field stays centred in the disc land.
5. Development — Open the aperture field and mounting features, then inspect for blocked holes or undeveloped fine webs.
6. Etching — Spray matched chemistry from both sides; etch time and temperature hold aperture size and open area within the filtration spec.
7. Stripping & Forming — Strip, neutralize and clean to an oil-free state, then form cups, domes or flanges where the housing needs them.
8. Inspection & Packaging — Verify aperture, open area, outline and flatness against the approved sample, then pack interleaved and protected.

Core Advantages

1. Aperture and open area on spec: Filtration rating and flow are set by artwork, so every disc matches the calculated micron rating and pressure drop.
2. No fibres or loose wires: Etched discs are solid sheet, so nothing sheds into fuel, air or fluid paths the way woven mesh can.
3. Disc and mesh in one part: Outline, aperture field and mounting holes are cut in a single operation, replacing mesh-plus-ring assemblies.
4. Flat, burr-free seating: Planar discs seat evenly against gaskets and housings, keeping the seal and the flow area predictable.
5. Fine micro apertures: Micro mesh filter parts hold 0.03–0.05 mm apertures in thin foil for demanding inlet and sensor protection duties.
6. Batch-to-batch consistency: Locked etch parameters and the same film reproduce discs across reorders, with measured aperture records per lot.

Typical Applications

• Fuel system filter discs: Fine aperture discs that protect injectors and pumps from particulate in diesel, petrol and kerosene lines.
• Pneumatic air filter discs: High open area screens for compressors and air preparation units where restriction must stay low.
• Hydraulic fluid screens: Robust stainless discs that catch wear debris ahead of valves and proportional controllers.
• Pump suction filters: Formed discs and cups that guard pump inlets without collapsing under suction differential.
• Sensor and regulator filter discs: Small precision discs that shield pressure sensors and regulator seats from line debris.
• Nozzle and dispenser screens: Compact micro aperture discs for spray nozzles, dispensing valves and metering fittings.

Design Notes & Process Considerations

1. Specify aperture plus open area: Give both numbers on the drawing — micron rating alone leaves too much freedom in the aperture field design.
2. Differential pressure check: Confirm the disc thickness and open area against worst-case pressure drop so the disc does not deflect in service.
3. Outer land and support: Keep a solid land of 0.5 mm or more around the aperture field for clamping, welding or flanging into the housing.
4. Forming drawings: For cups and domes, supply a formed drawing with radii and depth, since the flat etch pattern must account for stretch.
5. Cleanliness callout: Fuel and instrument duties usually need electropolishing, oil-free degreasing and protected packaging on the way out.
6. Multi-layer stacks: Where a coarse support mesh backs the etched disc, specify the layer order and bonding method so the aperture field is not shadowed.