Do you want to know wire mesh gasket
Wire mesh gaskets are precision-engineered sealing and shielding components manufactured from tightly woven or knitted metal wires—such as stainless steel, copper, aluminum, Monel, nickel, and tin-plated copper-clad steel. These gaskets deliver an unmatched combination of excellent electrical conductivity, corrosion resistance, mechanical durability, and EMI/RFI shielding effectiveness, making them indispensable across aerospace, defense, medical, telecommunications, and industrial electronics.
Construction & Design
Knitted wire mesh gaskets are formed by interlocking loops of metal wire into a flexible, compressible mesh structure. This asymmetrical interlocking wire loop design produces infinitely variable porosities when layered and compressed, creating an ideal medium for both shielding and sealing.
They are available in multiple configurations:
| Type | Description |
|---|---|
| All-Metal Gaskets | Constructed entirely from knitted wire mesh (e.g., Knitex®, MESH STRIP®). Highly resilient with spring-like loops. Suitable for temperatures from -60°C to 220°C depending on core material. |
| Elastomer-Core Gaskets | Two layers of wire mesh knitted around a core of neoprene, silicone, foam, or rubber. Provides both EMI shielding and environmental sealing (dust, moisture, vibration). Maximum deflection: ~30% with sponge elastomer, ~50% with hollow extrusion. |
| Compressed Mesh Gaskets | Die-compressed knitted wire mesh into jointless round or rectangular cross-sections (e.g., SHIELDMESH™). Ideal for small EMI seals like waveguide choke flanges. |
| Sock Screen Gaskets | Wire mesh filters fabricated to fit sanitary pipes (1"–8" diameter), typically in 316 stainless steel, used in food processing and pharmaceutical facilities. |
Available Profiles & Shapes
- Round / Circular — Most common; excellent shielding due to high metal density
- Rectangular — Standard cross-section for groove mounting
- P-Section — Features a fin for attachment to heatsinks or panels
- Double-Round / Double Core with Fin — Enhanced sealing for demanding applications
- Custom shapes — Including oval, D-shape, and tailor-made profiles
Standard dimensions range from 2mm to 32mm in width, with thicknesses from 2mm to 10mm, and general tolerances of ±0.8mm.
Materials & Their Properties
| Material | Wire Diameter | Key Properties |
|---|---|---|
| Monel (BS 3075 NA13) | 0.11mm | Corrosion-insensitive, galvanic-neutral |
| Tin-Plated Copper Clad Steel (SN-FE-CU) | 0.11mm | Excellent magnetic + electrical properties |
| Stainless Steel (AISI 304) | 0.11–0.13mm | Strongest option, comparable shielding to aluminum, highly wear-resistant |
| Aluminum (ALMG5 / 5056A) | 0.14–0.16mm | Lightweight, ideal for aluminum enclosures |
| Tinned Copper (BS 4109) | 0.11mm | Superior conductivity |
| Silver Clad Copper (BS 4190) | 0.12mm | Highest conductivity available |
| Copper (BS 4109) | 0.12mm | Outstanding EMI attenuation |
| Nickel Plated Copper | 0.15mm | Corrosion-resistant, high conductivity |
| Phosphor Bronze / Brass | Special order | Specialized applications |
Shielding Performance
Wire mesh gaskets deliver high EMI/RFI attenuation across a broad frequency spectrum. For example, at a standard 127mm × 127mm aperture:
| Material | 100 kHz (Magnetic) | 10 MHz (Electric) | 1 GHz (Plane Wave) | 10 GHz (Plane Wave) |
|---|---|---|---|---|
| Sn/Ph/Bz (Tin Phosphor Bronze) | 80 dB | 130 dB | 95 dB | 95 dB |
| Sn/Cu/Fe (Tin Copper Clad Steel) | 60 dB | 125 dB | 80 dB | 80 dB |
| Monel | 60 dB | 125 dB | 80 dB | 80 dB |
Note: For highest-frequency shielding, foil-based gaskets (e.g., Amucor Shield) may outperform mesh due to larger contact surface area.
Installation Methods
Wire mesh gaskets can be secured using:
- 🔩 Groove mounting — held by sidewall friction (most common for all-metal)
- 🧴 Conductive adhesive / glue
- 🔨 Riveting
- ⚡ Spot welding / soldering
- 🔧 P-section fin attachment via metal plate