The Manufacturing Process Behind Tech-Mesh™: From Raw Materials to Customization

Innovation is the driving force that keeps us moving forward. Tech-Mesh™, the exceptional knitted wire mesh product from CWI, is a prime example of how innovation and precision engineering can redefine industry standards. But what exactly goes into the making of Tech-Mesh™? In this blog, we'll take you on a journey through the intricate manufacturing process from raw materials to customization options. 

1. Rod Processing: The Foundation of Quality

Every great product starts with top-quality raw materials, and Tech-Mesh™ is no exception. The manufacturing process begins with wire rods, typically made of materials like stainless steel, Monel®, or other specialized alloys. Incoming raw wire rods is typically hot rolled, solution annealed, and acid pickled. The wire rod is then pre-coated in preparation for the breakdown stage.  

2. Rod Breakdown: Creating Precision

Once the wire rods are prepared, they move to the rod breakdown stage. Here, the larger diameter wire mill rod coils are reduced to sizes suitable for further processing. Central Wire stocks a variety of redraw sizes that can be processed to the finished wire diameter. Precision is key during this step to ensure that the wire maintains its intended diameter and tensile strength. 

3. Drawing Process: Getting the Right Diameter

The drawing process is where the wire is further sized to achieve the desired diameter and tensile strength. There are different methods employed for this purpose: 

• Dry Drawing: This method involves coating the wire with a dry lubricant and is typically used for larger diameters where surface area reductions are low. It results in a matte appearance on the wire, which may be preferred for certain applications. 
• Wet Drawing: Smaller diameters benefit from wet drawing, where the wire is processed in a liquid lubricant, such as water or petroleum-based grease. This method produces a bright, smooth surface finish and is suitable for diameters under .040". 

4. Annealing Process: Enhancing Mechanical Qualities

Annealing is a critical step in the manufacturing process of Tech-Mesh™. After the wire has been drawn to its desired thickness, it undergoes controlled heating and cooling. This process improves the wire's mechanical qualities and ensures maximum performance. It also reduces internal stresses that may have built up during the drawing process, increasing ductility and flexibility—essential properties for Tech-Mesh™ to perform under challenging environments. 

5. Knitting Process: Precision in Design

The heart of Tech-Mesh™ lies in its knitting process. Each individual wire is meticulously knitted together in a precise and complex design. Specialized technology is used to connect the wires, ensuring uniformity and accuracy in the mesh pattern. The knitting process directly impacts the final properties of Tech-Mesh™, including rigidity, flexibility, and strength. Different knitting patterns, whether open or tight, are chosen to meet the specific requirements of various applications. 

6. Crimping Process: Enhancing Structural Integrity

In some variations of Tech-Mesh™, crimping is employed to improve structural integrity and lifespan. During this process, woven wires undergo localized compression or distortion, creating mechanical interlocks between adjacent wires. This fortifies the mesh structure, making it more resistant to deformation or damage. Crimping is especially beneficial for Tech-Mesh™ wires that will face external forces or mechanical stress, such as safety barriers or protective enclosures. 

7. Support Frame Construction & Attachment: Maintaining Shape and Stability

In certain applications, Tech-Mesh™ may require a support frame to maintain its correct shape, structure, and stability. These support frames are constructed from robust materials like metal or polymer, complementing the Tech-Mesh™ and providing essential structural support. During attachment, various methods such as welding, clamping, or mechanical fastening are used to create a strong and long-lasting connection between the Tech-Mesh™ and the support frame. 

Customization Options: Tailoring Tech-Mesh™ to Your Needs 

One of the unique strengths of Tech-Mesh™ is its ability to be customized to meet the specific requirements of diverse projects and industries. CWI's in-house technical team, including metallurgists and technologists, collaborates closely with customers to create tailored solutions. Whether it involves modifying wire composition, adjusting mesh density, fine-tuning measurements, or addressing other unique characteristics, this customization capability ensures that Tech-Mesh™ performs optimally in a variety of applications. 

The journey from raw materials to customized Tech-Mesh™ is a testament to the precision engineering and dedication to quality that CWI brings to every product. Tech-Mesh™ stands as a reliable, long-lasting, and high-performing knitted wire mesh solution, ready to meet the demands of diverse industries by offering customized solutions backed by technical expertise and manufacturing excellence. 

At CWI, our commitment to excellence and innovation ensures that Tech-Mesh™ continues to be a driving force in redefining industry standards. Our meticulous manufacturing process reflects our dedication to delivering adaptable, premium-quality products that empower our customers and industries for generations to come.