Expanded Mesh vs. Perforated Metal: Which Should You ...

As we know, when it comes to expanded metal mesh, it isn&#;t just about the type or thickness of metal that matters; it is about the pattern intricacies that have a significant impact on both the functionality and the aesthetic quality of the final product.

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Diamond Pattern: Among the most iconic and widely recognised patterns of expanded metal mesh, the diamond pattern is what most people envision when they think about expanded metal mesh. With its symmetrical, versatile design, it offers an optimal balance between strength, airflow, and visibility. From walkways to fences, its consistent pattern provides a harmonious appearance that makes it a go-to choice for a wide range of applications.

Hexagonal Pattern: A six-sided pattern like honeycomb offers a distinctive aesthetic and structural advantage due to its resemblance to honeycombs. By providing an even distribution of weight and stress, it ensures that the product will last for a long time. In addition to that, its unique appearance gives architectural applications a modern touch that makes them stand out from the crowd.

Square Pattern: There is no better choice than the square pattern if you are looking for a more geometric and contemporary look. A uniform and regular design makes it an ideal option for facades, screens, and decorative partitions, as it provides uniformity and regularity in design. Additionally, the straight lines and angles provide an alternative to the traditional diamond pattern, presenting a clean and orderly appearance as compared to the traditional diamond pattern.

It is important to note that each pattern in expanded metal mesh serves a specific purpose and offers a unique visual dynamic to the user. In order to ensure that the mesh aligns perfectly with the project&#;s goals, it is vital to consider both the aesthetic preferences and the functional requirements, whether you choose the classic diamond shape, the nature-inspired hexagonal shape, or the modern square shape.

If you are looking for a product that will allow ventilation, drainage, or perhaps add a decorative touch, your three main choices are Expanded Sheet Metal, Perforated Sheet Metal, or Welded/Woven Wire Mesh. So which one do you choose and why?

There are three main differences between expanded metal, perforated metal and wire mesh:

• The ways they&#;re manufactured
• Their characteristics
• Their end-uses

Manufacturing Process

Expanded metal sheet

Expanded metal sheet is made by first creating multiple slits in the sheet, and then stretching the sheet. The stretching creates a unique diamond pattern opening with one of the strands protruding at a slight angle. These raised strands can be flattened later in the process if desired. As you can see this process creates no waste (thus keeping down production costs) and it can add structural strength to the product.

Perforated metal sheet

Perforated metal sheet is a product that is made from sheet steel that has been fed through a machine that punches out round holes (or other designs). These holes can be straight rows or staggered to increase the amount of the openings. Typically the perimeter of the sheet has a boundary where holes are not punched; this adds stability to the sheet. The removed metal from the holes can be recycled but it also increases the cost of the product. The larger the hole size (or increased amount of holes), the greater scrap volume, and therefore costs can be increased.

Wire mesh (welded)

Welded wire mesh is a metal wire screen that is made from various alloys including steel, stainless steel, brass and copper.  It is available in various sizes and shapes. Grids of parallel longitudinal wires are welded to cross wires at the required spacing, using electric fusion. The machines that are used to produce the mesh have precise dimensional control.

Wire mesh (woven)

Also available in steel, stainless steel, brass and copper, woven wire mesh is made as a cloth with wire threads woven at right angles. Wires which run lengthwise are known as warp wires, whilst those running perpendicular are weft wires.There are two common styles of weave: plain weave and twill weave. It can be made from various alloys including stainless steel, brass and copper. Wire cloth can be woven to create a variety of opening sizes and wire diameters.

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Characteristics

Expanded metal sheet

One of the benefits from the manufacturing of expanded metal is that the sheet retains its structural integrity because it has not undergone the stress of having shapes punched in it (like perforated sheet), and the mesh-like pattern will not unravel (like woven mesh can do). Expanded metal has been stretched rather than punched, reducing scrap metal waste; making it cost-effective. The main considerations when using expanded metal will be the chosen thickness and strand dimensions (weight and structural design requirements). Expanded metal can be almost transparent (depending on the opening); it has mechanical properties and is an excellent conductor.

Perforated metal sheet

Perforated metal sheet comes in a virtually endless variety of sizes, gauges, hole shapes and material types. Hole diameters range from a few thousandths of an inch to more than 3 inches, punched in material as thin as foil or as thick as 1-inch steel plate. From lightweight decorative elements to load-bearing structural components, perforated metal offers unique opportunities to combine strength, functionality and beauty.

Wire mesh (welded)

The chance of improper bending of bars is reduced since bending machines bend the mat as a single unit. This provides the exact size of reinforcement where needed through variable bar size and spacing, thereby reduces steel waste. There can be a considerate savings because mesh is easy to handle and can be installed much faster. Typically you can purchase a welded mesh for less than a woven mesh.

Wire mesh (woven)

Wire mesh is adaptable to almost any application. It is extremely durable and very easily cleaned.

Typical end uses

Expanded metal sheet

Expanded metal sheet works well for steps, flooring in factories and on construction rigging, fences, wash stations, and security applications.

Perforated metal sheet

Perforated metal can be made into a multitude of products such as: screens, filters, baskets, trash cans, tubing, light fixtures, vents, audio speaker covers and patio furniture.

Wire mesh (welded)

Widely used in agricultural applications, industrial, transportation, horticultural and food procuring sectors. It is also used in mines, gardening, machine protection and other decorations.

Wire mesh (woven)

From sifting and screening machinery to conveyor and automotive belts, all the way to animal enclosures and architectural framework.

Don&#;t have time to read the blog?

You can check out our video below to find out the difference between expanded metal, perforated metal and wire mesh:

Are you interested in learning more about perforated mechanical guard mesh? Contact us today to secure an expert consultation!