High-End Etched Metal Filter Mesh with Superior Uniformity & Burr-Free Surface for the US Market

High-End Etched Metal Filter Mesh with Superior Uniformity & Burr-Free Surface for the US Market

Product Overview

Xinhaisen is a professional manufacturer of precision metal etched parts. Our Precision Etched Metal Filter Meshes are high-performance filtration solutions crafted for demanding applications across various industries. Utilizing advanced chemical etching technology, we produce flat, burr-free metal screens with exceptionally fine and precise hole patterns. These filters are designed to provide consistent and reliable performance in critical environments, from medical devices and automotive systems to consumer electronics and food processing equipment.

Manufacturing Process

Our metal filter meshes are manufactured using a precise photo-chemical machining (PCM) process, which offers distinct advantages over traditional stamping or laser cutting:

• Tooling Design: A precise CAD file of the filter pattern is created.

• Photographic Film: The CAD design is printed onto a high-resolution photographic film, which acts as a tool (mask).

• Material Preparation & Lamination: High-quality metal coils (such as stainless steel) are thoroughly cleaned and laminated with a photosensitive resist film on both sides.

• Exposure & Development: The film mask is placed onto the metal sheet, and UV light is used to transfer the image, hardening the resist in the pattern of the filter. The unexposed, soft resist is then chemically washed away during development, leaving the bare metal exposed in the areas that will become the holes.

• Etching: The metal sheet is passed through a series of high-pressure spray chambers where an etchant solution precisely dissolves the exposed metal, creating the desired hole patterns from both sides simultaneously.

• Stripping & Cleaning: The hardened protective resist is chemically stripped away, revealing the finished, clean precision metal filter mesh.

Product Features

• Ultra-High Precision: Achieves extremely fine details, with micro-holes as small as 0.03mm and line widths down to 0.015mm.

• Burr-Free & Flat: The chemical etching process produces perfectly flat screens with absolutely no burrs, sharp edges, or deformities, ensuring a perfect seal and preventing contamination.

• Material Versatility: Capable of etching a wide variety of metals, including stainless steel (SUS304, SUS316L), copper, titanium, and other alloys.

• Design Flexibility: Easily accommodates complex hole shapes (round, square, slotted) and patterns without the high cost of hard tooling dies. Design changes can be implemented quickly.

• Consistent Uniformity: High uniformity with tolerances maintained at ±0.01mm, guaranteeing reliable and predictable filtration performance across large production volumes.

• Thin Gauge Capability: Ideal for processing thin materials from 0.02mm to 1.5mm thick, allowing for lightweight and space-saving filter designs.

Product Specifications

Product Applications

Our precision-etched metal filters are essential components in a wide range of industries:

• Electronics & Acoustics: Speaker and receiver meshes, microphone grilles, EMI shielding filters.

• Medical Technology: Filter screens for medical devices, surgical instruments, and diagnostic equipment.

• Automotive: Fuel injection filters, airbag components, anti-splash screens for sensors.

• Industrial Filtration: Hydraulic and pneumatic filter discs, screen filters for protection of nozzles and valves.

• Household Appliances: Filter meshes for coffee machines, juice extractors, vacuum cleaners, and air conditioners.

• Precision Engineering: Optical apertures (gratings), scraper blades, masks for surface mounting technology (SMT).

Why Choose Xinhaisen?

• Technical Expertise: We specialize in etching complex and ultra-fine features, including micro-hole perforations, ensuring high-quality filtration media.

• Rapid Turnaround: Our advanced production capabilities allow us to handle urgent and high-volume orders with exceptional speed and efficiency.

• Consistent Quality: We maintain strict process control to deliver products with high precision and uniformity, ensuring perfect integration into your assemblies.

• Material Versatility: We have extensive experience etching various metals to meet specific application requirements for durability, corrosion resistance, and strength.

• Customer-Centric Approach: We collaborate closely with our clients to provide custom solutions, from prototype to mass production, earning a strong reputation for reliability and excellence.

FAQ

Q: What are the main advantages of etched metal filters compared to woven wire mesh?
A: Etched metal filters are flat, rigid, and have precisely defined, consistent hole sizes and shapes. They are burr-free and offer greater structural integrity than woven mesh, which can have varying aperture sizes and may fray or distort over time.

Q: What is the smallest hole size you can etch?
A: Leveraging our advanced etching capabilities, we can reliably produce micro-holes as small as 0.03mm in diameter on various metal thicknesses.

Q: What types of metal can you use for etching filters?
A: We work with a wide range of metals, with stainless steel (SUS304, SUS316L) being the most common due to its strength and corrosion resistance. We can also etch copper, titanium, and other specialty alloys based on your project needs.

Q: Can you manufacture custom shapes and patterns?
A: Yes, absolutely. Our photo-chemical etching process is incredibly flexible. We can produce any 2D shape or hole pattern you require. Custom designs do not require expensive tooling, making it a cost-effective solution for prototypes and custom runs.

Q: What is the typical lead time for a custom order?
A: We pride ourselves on our speed and flexibility. After design approval, sample lead times are very fast, and we can quickly move to full-scale production to accommodate both small trials and large, urgent orders. Please contact us with your specific requirements for an accurate timeline.

Welcome to contact us at any time!