MicroGrid® Precision Expanded Metal and Metal Foil
- One-piece, single-unit structure
- Eliminates unraveling and contact resistance of woven mesh
- Superior shielding, electrical and heat transfer properties
- Wide range of sizes, patterns, angles and materials
- Specialized process variations, such as flattening, pulling, and annealing available
MicroGrid® precision-expanded foils from Dexmet are used in batteries, electronics, aerospace, medical, packaging, and wherever mesh and perforated foils with high precision, mechanical and electrical properties or EMI/ RFI shielding capabilities are required. They are available in most metals and polymers, or we can work with your proprietary materials. Metals we regularly produce include: aluminum, brass, copper, Monel™, nickel, steel, stainless steel, and zinc.
From our expanded metal a range of standard diamond mesh sizes from .416″ to .020″ is available. The number of openings per square inch can vary from 25 to as many as 11,000, with an open area from 95% to as low as 10%. The variable open area facilitates lamination with a variety of other materials, including those which expand, contract and flex. We’ll even design a precision expanded foil or expanded metal with unique characteristics for your particular application. Dexmet’s extensive manufacturing resources can accommodate many process variations for metal materials in a range of finished thicknesses.
(Long Way of the Diamond), measured from the center of the joint to the center of the adjacent joint. This dimension is built into the tool, and is always parallel to the width of the coil and corresponds with the diamond dimension.
(Short Way of the Diamond) is the length of the short axis way of the diamond, measured from the center of the joint to the center of the joint. For each fixed LWD dimension, there is a range of SWD dimensions available as shown above.
Aluminum, Brass, Columbium, Copper, Gold, Inconel, Nickel, Nickel Alloys, Phosphor Bronze, Platinum, Silver, Stainless Steel, Low Carbon Steel, Tantalum, Titanium, Zinc, Zirconium, etc.
PEEK, PTFE, PFA, ECTFE, Polypropylene, Polyethylene, Mylar, Tefzel, etc.
Explanation of Product Code:
Example: 3 Ni 5-077
First number represents nominal original thickness
3 = .003″ (.076 mm)
Letters are chemical symbol for material
Ni = Nickel
Number immediately following letters represents strand width
5 = .005″ (.127 mm)
Last number indicates the long way of the diamond
077 = .077″ (1.96 mm)
Variations to many of these standard MicroGrid® products are described in the previous section. In addition, each mesh size offers a wide range of tools for your desired results. We can help design precision expanded foil to meet your specialized mechanical, electrical, or heat transfer requirements. Call for material/mesh samples and engineering assistance.
Below sample images are for reference only.
3 Brass 10-125
20 Al 20-416
10 Cb 20-284
The chart below is in inches
|Tool Code||LWD (in)||SWD Min (in)||SWD Max (in)||Hole Size Min (in)||Hole Size Max (in)||Opening SQIN Min||Opening SQIN Max||Open Area Min||Open Area Max||Width (in)||Raw Thickness Min (in)||Raw Thickness Max (in)|
|Hole Size (in)||Opening/
The chart below is in millimeters
|Tool Code||LWD (mm)||SWD Min (mm)||SWD Max (mm)||Hole Size Min (mm)||Hole Size Max (mm)||Opening SQCM Min||Opening SQCM Max||Open Area Min||Open Area Max||Width (mm)||Raw Thickness Min (mm)||Raw Thickness Max (mm)|
|Hole Size (mm)||Opening/
Process Variations for Specific Expanded Metal Applications
Dexmet’s process variations can meet your requirements for specific material qualities, including thickness, strength, conductivity, resistivity, corrosion resistance and ease of material handling. The samples included throughout this Web Site demonstrate the interesting versatility of several variations. Please be sure to note the availability of Dexmet’s specialized manufacturing features.
Variable Overall Thickness
After the material is expanded, the overall thickness of the mesh is greater than the original metal thickness. The final mesh thickness can be controlled to meet your needs. Each configuration has a practical range of overall thickness.
As a rule of thumb, the maximum thickness is 1.6 times the strand width. The minimum thickness is the original metal thickness, or slightly below the original thickness in the case of a reduced product. For example, the range for 5 Cu 7-125 would be .004″ – .011″. The overall thickness is not specified in the product code. Simply tell us what you require.
The flattening process reduces material thickness and creates a smoother mesh surface that’s similar to perforated metal. Pocket depth is also reduced or eliminated. The flattening process increases material coverage while reducing the size of the open mesh area. Please consult the company for further information on flattening.
Pulling the mesh after expanding can result in several desirable features. Pulling changes the shape of the opening. It increases the overall thickness in most configurations, and can increase the stiffness or tensile strength. Distex Brick material creates a deeper pocket, to accept more filler or coating, and adds longitudinal strength in some configurations.
Double Distex Brick
Double pulling of the material changes the shape, so that the long way of the opening runs with the coil. Double pulling can also be used to change the symmetry of the electrical conductivity.
Custom-designed, selvage edge equipment folds over the edge of the MicroGrid® material to the desired width. The resulting closed edge provides greater strength in the direction of the coil. Selvaging is a perfect example of our response to customer requests. Easier material handling, increased safety, and ease of use were all requests which selvaging accomplished by eliminating the normally rough edge. Many engineers also find that the selvage edge can be soldered or welded more easily.
Dexmet can provide MicroGrid® configurations with solid (unexpanded) metal portions combined with expanded metal portions. Expanded/solid combination metal foils offer a wealth of new applications.
Dexmet has developed a proprietary process that continuously anneals long rolls of MicroGrid® foils. Strand-annealed stainless steel provides excellent corrosion resistance, as well as consistent levels of tensile strength and flexibility. In fact, the enhanced corrosion resistance achieved with the process often permits the replacement of a more expensive foil, such as titanium, for many applications. Dexmet also has equipment to perform batch annealing, the traditional method for annealing copper, silver and aluminum.
Dexmet’s annealed MicroGrid® foil mesh is also soft and flexible, very bright and clean, and exceptionally flat. The annealing process retains the precision shape, tightness and straightness of the foil material without stretching. The annealed material can be precision-manufactured to specification for unique electrical and mechanical characteristics.
Numerous applications require a coating or hermetic sealing to prevent oxidation, corrosion or galvanic action with adjacent materials. Or, more expensive materials like nickel may be plated on a lower-cost substrate like steel to reduce overall material costs. Tin on copper is another common combination. Coatings normally add no appreciable thickness or weight and may be metallic or polymer, conductive or nonconductive.
Customers frequently turn to us to provide a finished piece, blanked to specification. Dexmet blanks parts from MicroGrid® materials for some of the most critical applications, and we are always prepared to discuss your needs.
In addition to blanking, Dexmet can also offer various forms of fabricating and subassembly work. Please call us to discuss your specific needs.
Packaging and Delivery Systems
Whether our unique, recyclable blue spools; special splicing; weight and outer-diameter criteria; or just-in-time delivery is called for, we’ll work with you to ensure that your MicroGrid® arrives when, where and how you want it.
Other Value-Added Services
Dexmet engineers are always ready to assist you with your unique product development or process integration issues. We can also help with your overseas requirements, from crating to customs and freight forwarding. Let us assist with your MicroGrid® product.
Phone: (203) 294-4440
Fax: (203) 294-7899
22 Barnes Industrial Rd. So.
Wallingford, CT 06492
United States of America
The Battery Show – Europe
April 4-6, 2017
Stuttgart, Germany – Booth# B136
Information on The Battery Show Europe