Wire Mesh - What's the Best Molded Fiber Screen?

Wire Mesh - What's the Best Molded Fiber Screen?

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With the world's growing shift toward sustainability, the molded fiber industry is experiencing significant growth. Molded fiber is vital in creating environmentally friendly products, from protective packaging for electronics to recyclable food containers.

To craft these molded fiber products, several materials and tools are essential. Among these, screening materials like woven wire and welded wire mesh play a pivotal role in ensuring the quality and efficiency of molded fiber production.

This brings us to the question: What are the differences between these materials, and which one should you choose?

At W.S. Tyler, our rich 150-year history in woven wire production enables us to provide customized solutions that help our clients succeed in the molded fiber industry.

To aid your decision-making, we've put together this comprehensive guide comparing woven wire mesh and welded wire mesh. We'll cover:

• The definition of woven wire mesh
• The definition of welded wire mesh
• The benefits of both woven wire mesh and welded wire mesh
• The disadvantages of both woven wire mesh and welded wire mesh
• Which material you should choose

What Is Woven Wire Mesh?

Woven wire mesh is a versatile screening material created by interweaving hundreds of metal wires. This creates a grid-like structure that balances strength, flexibility, and precision, making it suitable for various applications.

One of the reasons for its widespread use is its customizability. Parameters like weave thickness, weave pattern, alloy, and mesh count can all be adjusted to fit your operation's needs.

What Is Welded Wire Mesh?

Welded wire mesh is created by laying metal wires in a grid pattern and welding them together at each intersection. Known for its uniform openings and increased strength, welded wire mesh excels in demanding applications.

It is often available with coatings or galvanization, enhancing its long-term stability and durability.

Why Use Woven Wire Mesh?

Woven wire mesh is flexible, making it ideal for forming intricate, detailed molds used in molded pulp production. It provides a smooth, high-quality surface and offers efficient water drainage, reducing energy costs during drying stages.

Its flexibility and higher open area percentage prevent pulp fibers from clogging the mesh, reducing maintenance and downtime.

Also, woven wire can be customized for a variety of applications.

The Disadvantages of Woven Wire Mesh

Budget is always a concern. Woven wire tends to be more expensive than welded wire mesh.

While flexible, it may be less rigid than welded wire mesh, particularly with finer specifications.

This flexibility can lead to mesh movement in high-pressure applications, particularly if lower-quality alloys or unreliable weaving processes are used.

Due to its less durable nature, woven wire can be more challenging to handle and install.

Why Use Welded Wire Mesh?

Welded wire mesh is much more rigid than woven wire, maintaining structural integrity under heavy stress. This rigidity translates to superior durability in high-stress environments.

One obvious advantage is cost. Welded wire mesh is generally less expensive than woven wire mesh.

The welds create a permanent bond, keeping the mesh openings fixed and maintaining consistent product quality.

Its rigid nature makes it easier to handle and install, making it a more convenient option for many applications.

The Disadvantages of Welded Wire Mesh

The rigidity of welded wire mesh limits its flexibility, making it challenging to form complex, detailed shapes.

Deep drawing is crucial in forming molded fiber screens. Learn more about this process in the articles below:

The lack of flexibility can result in clogged pore openings, reducing drainage capacity and increasing maintenance time.

While durable, welded wire mesh can be susceptible to corrosion or breaks at the weld points, particularly in harsh environments.

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Which Should I Use for My Molded Pulp Process: Welded Wire Mesh or Woven Wire Mesh?

Choosing the right material for your molded pulp screens depends on your specific needs. Consider factors like budget, product quality requirements, and operational conditions.

If you need a material with the flexibility to create detailed, intricate shapes, woven wire mesh is ideal. If cost-effectiveness and structural integrity are your main concerns, welded wire mesh may be the better choice.

If you still need guidance, W.S. Tyler is available to offer insights into how different mesh types can impact your molded pulp operations.

Take Your Process to Greater Heights With the Right Wire Mesh Alloy

Both woven wire mesh and welded wire mesh are crucial for molded fiber screens. Woven wire provides flexibility and detail, while welded wire offers durability and cost benefits.

Choosing the right alloy for your wire mesh is essential for long-lasting performance. With over 150 years in the woven wire industry, W.S. Tyler is committed to providing high-quality screening materials to support your green initiatives.

Read the following article to understand different alloys used for molded fiber screens:

Woven Wire Mesh vs. Welded Wire Mesh

There are many characteristics to consider when selecting the right wire mesh product for your project. One of the primary differences between Woven Wire Mesh and Welded Wire Mesh is how they are constructed, or how the wires intersect. Woven Mesh is formed when cross wires and line wires are crossed over and under each other.

Wire Mesh is classified as Welded Wire Mesh when its wire intersections are melted and cooled together. Nevertheless, the differences and capabilities of these two categories of mesh go far beyond their methods of construction.

Which Type Is Stronger?

Since the bonds of Welded Mesh are fused together, they provide a certain level of rigidity and strength. They maintain their fixed opening shape even under force. However, if outside pressures put too much stress on Welded Wire Mesh intersections, a breaking point exists where welded bonds can eventually snap.

Woven Mesh does not have fixed bonds, so it is pliable and does not possess the rigid qualities of its welded counterpart. However, the flexibility of woven items allows the product to yield under outside pressure before springing back. These characteristics provide unique durability, especially in applications where stress applied to wire mesh is a crucial consideration.

Why Does Opening Size Matter When It Comes to Construction Type?

When deciding which construction type is right for you, the desired opening size (clear space between wires, measured from the inside edge of one wire to the inside edge of the next adjacent wire) will be an important factor. Generally, Woven items are available with smaller opening sizes, while Welded is better suited for applications that call for larger openings.

For Welded, the smaller the desired opening size, the smaller the wire diameter has to be to leave enough clear opening for the welding process to occur between the wires. However, if the wire diameter becomes too small, the heat generated from the welding process can melt the wires.

For these reasons, the smallest opening size offered for Welded is typically 4 x 4 Mesh (four openings per linear inch measured from the center of the wires), although a few smaller Mesh sizes are available in Stainless Steel and PVC-coated finishes.

Woven items are often unavailable in larger opening sizes common in welded items. Without welded bonds to hold them in place, woven wires can shift and lose their original shape. If you need a larger opening size but still require a woven construction, Lock Crimp and Intercrimp weave types provide increased rigidity.

Will Wire Mesh Unravel?

Woven items are not bonded at each intersection, so it is possible for wires to come apart at pattern ends or where the material is cut. Larger opening sizes and smaller wires reduce the rigidity of woven items, making them more likely to unravel at the ends once sheared.

Some woven meshes come with a selvage or finished edge. One common method is curling the shute (short) wire and weaving it back through the warp (long) wires. These looped ends help prevent unraveling. Other methods include framing the material or leaving a stub to hold the ends in place for larger openings.

Lock Crimp and Intercrimp weaves are more likely to stay together once sheared but are also not permanently fastened and can come apart. Since Welded Wire Mesh is secured at each intersection, it is less likely to come apart once cut.

What Materials and Finishes Are Available?

Wire Mesh is formed in various material types and finishes, though there are limitations depending on the construction type. For example, Welded Mesh is unavailable in aluminum because the metal tends to be too soft and susceptible to melting. Additionally, although pre-galvanized woven materials are available, they are generally not hot-dipped galvanized after weaving.

Hot-dipped galvanizing and powder coating are not ideal for woven items because the coating process may not cover areas where wires overlap. This can expose uncoated steel to corrosive elements.

What Is "Coil Memory"?

Wire Mesh is available in coil and sheet forms. Typically, Woven Wire Mesh is stored as coils or rolls. When coiled materials are unrolled, cut pieces may retain their coiled shape rather than lying flat. This is known as "coil memory."

To reverse the coil shape, pieces can be flipped and laid flat with a heavy object placed on the surface. However, care should be taken not to crush the wires or weave pattern.

With Welded Wire Mesh, the fused intersections make it very stiff, making it more difficult to roll into tight coils. Therefore, Welded Wire Mesh is typically stored in sheet form. The "coil memory" phenomenon is more common with woven items due to their thinner wires.

Summary

While Woven and Welded wire mesh may look similar, significant differences make each suitable for specific applications. Understanding these characteristics helps determine which type is best for your needs.

If you have any questions or need assistance in selecting the right wire mesh, contact us at 866.252.9064, sales@mcnichols.com, or via Live Chat on mcnichols.com.

Contact us to discuss your requirements for a Hot dipped galvanized welded wire mesh roll. Our experienced sales team can help you identify the best options for your needs.