What is Production Process of Wire Mesh Exactly?

Time:2023-07-04 Read:9

The production process of wire mesh typically involves the following steps:

Production Process of Wire Mesh.jpg

Wire Selection: High-quality wires made of various materials such as stainless steel, carbon steel, copper, or aluminum are chosen based on the intended use of the wire mesh. The wires come in different diameters and surface treatments.
Wire Straightening: The as-received wires are often coiled and may have some curvature. They are passed through wire straightening machines to ensure they are straight and ready for further processing.

Plain Weave: In this method, the warp wires (running lengthwise) and weft wires (running crosswise) are interlaced in a simple over-and-under pattern. Each warp wire passes over and under successive weft wires, creating a flat and uniform mesh structure.
Twilled Weave: The twilled weave involves a more complex interlacing pattern. Here, the warp wires pass over two or more weft wires and then under two or more weft wires, creating a diagonal pattern on the surface of the mesh.
Dutch Weave: Dutch weave is a special type of weave that uses a combination of thick and thin wires. The thick wires are used for the warp, and the thin wires are used for the weft. The thin weft wires are woven very tightly around the warp wires, resulting in a very fine and dense mesh.

Spot Welding: In spot welding, the intersection points of the wires are joined together by applying heat and pressure. Electric current is passed through the wires at the intersection points, causing the metal to melt and fuse together.
Projection Welding: Projection welding is similar to spot welding, but instead of welding at the direct intersection points, small projections or bumps are formed on one or both of the wires. These projections concentrate the heat and pressure at specific points, resulting in stronger welds.

Cutting to Size: After weaving or welding, the wire mesh is cut into the desired sizes and shapes according to the specific requirements of the application. This can be done using various cutting methods such as mechanical cutting, laser cutting, or water jet cutting.
Edge Treatment: The cut edges of the wire mesh may be sharp and need to be treated to prevent injury and to improve the appearance. Edge treatment methods include bending the edges, applying protective coatings, or using edge binding materials.

Galvanizing: Galvanizing is a common surface treatment method used to protect the wire mesh from corrosion. It involves coating the wire mesh with a layer of zinc, either by hot-dip galvanizing or electro-galvanizing.
Powder Coating: Powder coating is a process in which a dry powder coating material is applied to the surface of the wire mesh and then heated to form a durable and decorative coating. Powder coatings come in a variety of colors and finishes.
Painting: Painting can also be used to protect the wire mesh and enhance its appearance. Different types of paints, such as epoxy paints or acrylic paints, can be applied using spray painting or brush painting techniques.

Visual Inspection: The wire mesh is visually inspected for any defects such as missing wires, loose wires, uneven weaving or welding, and surface imperfections. Any defective areas are identified and marked for further processing or rejection.
Dimensional Inspection: The dimensions of the wire mesh, such as the wire diameter, mesh size, and overall size, are measured to ensure they meet the specified requirements.
Strength Testing: The wire mesh may be subjected to strength testing to evaluate its tensile strength, tear resistance, and other mechanical properties. This helps to ensure that the wire mesh can withstand the intended loads and stresses.

Packaging: The inspected wire mesh is then carefully packaged to protect it during transportation and storage. Common packaging methods include wrapping the wire mesh in plastic film, placing it in cardboard boxes, or using wooden pallets for larger quantities.
Shipping: The packaged wire mesh is shipped to customers or distribution centers using various transportation methods such as trucks, trains, ships, or airplanes, depending on the destination and quantity.