Overview

A micro medical mesh for atomizers is an ultra-thin foil perforated with thousands of 0.02–0.05 mm holes that vibrate to draw liquid through and generate a respirable aerosol in a medical nebulizer. The hole diameter is the dose: it sets the droplet size that decides whether the drug reaches the lower lung, so every aperture on the disc must be nearly identical. Photochemical etching images the entire hole array in one exposure on 0.02–0.15 mm 316L, titanium or nickel foil, then opens the holes chemically to leave round, burr-free entries with no recast layer and no loose particle that could be inhaled.

Medical use adds a cleanliness and consistency layer on top of the geometry. Foil is electropolished to smooth the hole walls, passivated for corrosion resistance against drug formulations, ultrasonically cleaned and packed in a clean environment, with each lot traceable under ISO 9001 process control. A micro medical mesh for atomizers holds hole diameter to ±0.003 mm and pitch to ±0.005 mm, so the aerosol output stays within specification from the first article through production volumes. Because the disc is processed as one panel under a single mask, dose uniformity does not drift with tool wear — the failure mode that punches and drills bring to hole counts in the thousands.

Parameter Window

• Available Materials: 316L stainless steel, titanium, nickel
• Material Thickness Range: 0.02–0.15 mm
• Tolerance: ±0.003 mm on hole diameter, ±0.005 mm on pitch
• Minimum Feature: 0.02 mm hole diameter, 0.04 mm pitch, thousands of holes per disc
• Surface Options: electropolish, passivation, ultrasonic cleaning, cleanroom packaging
• Compliance: ISO 9001 process control, RoHS/REACH material traceability

Manufacturing Process / Workflow (8 Steps)

1. Hole Array Artwork & DFM — Set hole diameter, pitch, count and taper, then compensate the mask for the etch factor on ultra-thin foil.
2. Biocompatible Foil — Select 316L, titanium or nickel foil with certified thickness and fine grain for 0.02–0.15 mm stock.
3. Clean Lamination — Degrease and laminate dry-film photoresist on both faces under clean, controlled conditions.
4. UV Exposure — Image the full hole array through a high-resolution registered mask so all apertures share one datum.
5. Development — Open the stencil and inspect the smallest holes under magnification for residue or bridging.
6. Controlled Etching — Spray etchant to open holes through the foil, holding ±0.003 mm on diameter with time and conveyor speed.
7. Stripping & Electropolish — Remove resist, electropolish and passivate, then ultrasonically clean the disc.
8. Clean Inspection & Packaging — Verify hole diameter distribution and open area, then pack in a clean environment with lot records.

Core Advantages

1. Tight dose control: Hole diameter to ±0.003 mm gives a consistent, respirable droplet spectrum.
2. No loose particles: Burr-free, electropolished holes shed no recast layer or metal debris into the aerosol.
3. Thousands of identical holes: One masked exposure keeps every aperture uniform across the disc.
4. Biocompatible, clean supply: 316L or titanium with passivation and clean packaging suits medical formulations.
5. Stress-free ultra-thin foil: Flat, 0.02–0.15 mm discs bond reliably into the vibrating actuator.
6. No tool-wear drift: A micro medical mesh for atomizers repeats from one film, so dose does not change as a punch wears.

Typical Applications

• Mesh nebulizers: Vibrating aperture discs in portable medical nebulizers.
• Inhalation drug delivery: Dose-forming meshes for respiratory therapeutics.
• Portable inhalers: Compact aerosol generators for handheld drug devices.
• Nasal and ocular sprayers: Fine-hole discs for controlled droplet delivery.
• Diagnostic nebulizers: Calibrated meshes in pulmonary function and aerosol test equipment.
• Veterinary and home-care devices: Atomizer meshes for home and animal health nebulizers.

Design Notes & Process Considerations

1. Diameter equals dose: Specify hole diameter and taper together, since both set the droplet size distribution.
2. Pitch and open area: State pitch, hole count and open area so the foil keeps enough web strength to vibrate.
3. Taper direction: Define the entry face, because single-side etching gives a conical wall and directional flow.
4. Cleanliness and packaging: Call out electropolish, cleaning and clean packing, as particulate is a medical risk.
5. Flatness for bonding: State flatness for the disc bonded to the piezoelectric actuator.
6. Lot traceability: Tie each batch to foil certificates, because a micro medical mesh for atomizers must be auditable for dose consistency.