Leading Expanded Metal Manufacturers

More Expanded Metal Manufacturers

Manufacturers often create expanded metal products for both decorative and functional purposes. These versatile materials offer a robust yet lightweight solution, enhancing the strength of any product made partially or entirely from them. Expanded metals provide protection while still allowing air to flow through, making them an ideal choice for various applications.

Products Produced

Expanded metal is a versatile material utilized in a myriad of applications, making its way into numerous products thanks to its unique characteristics. One of the most prevalent products crafted from expanded metal is grating. This type of grating is extensively employed in industrial settings, walkways, and platforms. Its open design facilitates efficient drainage and ventilation while offering robust support for heavy loads. Another significant use of expanded metal is in fencing and security products. The interlocking pattern of expanded metal is ideal for fencing, providing both visibility and security in various environments, such as airports, prisons, and commercial properties.

Expanded metal is widely utilized in architectural and decorative applications, offering both functionality and visual appeal. Architectural meshes crafted from expanded metal enhance the aesthetic of buildings and facades, delivering a distinctive and contemporary look. These meshes serve as sunscreens, privacy screens, and artistic installations, allowing designers to creatively manipulate light and shadow. Furthermore, expanded metal is used in automotive products like radiator grilles and protective covers, valued for its lightweight and durable properties.

In the realm of filtration and screening, expanded metal plays a vital role. It’s used to create air filters, oil filters, and screens for a variety of industrial processes. The precise openings in the expanded metal facilitate efficient filtration, making it the ideal choice for separating particles in liquids and gasses.

Furthermore, expanded metal plays a crucial role in the construction industry as reinforcement for concrete and masonry. When used as concrete reinforcing mesh, expanded metal significantly enhances the structural integrity and load-bearing capacity of concrete structures, thereby improving their durability and safety.

In essence, the adaptability of expanded metal makes it a prized material across numerous industries, resulting in the creation of an array of diverse products. Whether used in grating, fencing, architectural meshes, automotive components, or filtration systems, expanded metal is crucial in fulfilling structural, functional, and aesthetic needs in a variety of applications.

Expanded Metals – Dexmet Corporation

History

In 1884, John French Golding revolutionized the mining industry in the United Kingdom with his invention of the expanded metal process. His aim was to create a durable tray or metal screen that miners could use to sort coal more efficiently. Prior to Golding’s innovation, miners relied on sorting tools crafted from metal strips or woven wire, which were both inefficient and lacked standardization, as well as strength. Golding’s breakthrough involved using a single metal sheet, resulting in screens far more durable than their predecessors. Moreover, the expanded metal process produced screens with consistent and uniform open areas, greatly enhancing their effectiveness.

Five years after pioneering metal expansion, Golding and a group of industry experts combined their knowledge and research to establish a new company. Initially named the British Metal Expansion Company, it was later rebranded as the Expanded Metal Company Limited, based in London. For several years, the Expanded Metal Company held a monopoly on metal expansion in Europe, possessing exclusive rights to the process.

In the 1890s, Eli Hendrick, an American innovator, invented the punching machine, which served as the precursor to modern perforating punches. These perforating punches enable the creation of perforated metals, closely related to expanded metals.

Charles H. Schrammel was the first person in the United States to receive a patent for expanding metal. Awarded in 1910, his innovative work significantly improved the metal expansion process. Schrammel introduced sheet metal rolling to the process and altered the angle of metal mesh dividers, resulting in better textures for gripping.

Over the past century, the metal expansion process has largely remained consistent, with notable advancements driven by technological progress. Innovations such as automation, digital perforation, the establishment of standards organizations, and the advent of CNC machining have revolutionized the field. While the rise of plastics has slightly reduced the market share for expanded metals, the industry continues to flourish. Recently, a revived interest in classic architectural styles has spurred renewed demand for architectural perforated and expanded metals, leading to a significant increase in business for the expanded metal products industry.

Materials

Manufacturers craft expanded metal products from a variety of metals, with copper, aluminum, stainless steel, and titanium being the most frequently chosen. These metals are known for their exceptional strength and corrosion resistance, while still maintaining a relatively lightweight profile. After expansion, they can all be cold rolled to reduce their thickness, ensuring a more uniform and smooth surface.

Copper, a naturally occurring non-ferrous transition metal, is renowned for its exceptional electrical and thermal conductivity, antimicrobial properties, corrosion resistance, strength, and distinctive color. Manufacturers harness the versatility of copper expanded metal to create a diverse array of products, including metal grating, enclosures, filters, radiators, walkways, heat sinks, decorative ornaments, and intricate decorative metal mesh.

Aluminum, a naturally occurring element, is rarely used in its pure form but stands out for its lightweight, durability, and superior corrosion resistance compared to carbon steel. Notably, aluminum strengthens in cold temperatures instead of becoming brittle. Expanded aluminum is versatile, finding applications in refrigerator and freezer enclosures, guards, flooring, walkways, grilles, electronic and automotive components, marine and aquarium parts, cooking tools, and air filters.

Stainless steel, an alloy containing a minimum of 10% chromium, boasts a thin layer of chromium oxide on its surface. This unique feature grants expanded stainless steel products self-repairing capabilities when scratched, along with exceptional resistance to corrosion and rust. Compared to other steel alloys like mild steel,stainless steel is stronger, more durable, and highly resistant to bacteria. These attributes make expanded stainless steel invaluable in diverse environments, from kitchens, clinics, hospitals, and laboratories to outdoor applications, vehicles, buildings, water treatment plants, marine settings, and airplanes.

Titanium boasts exceptional strength, lightweight properties, resistance to corrosion and heat, and sterility. It matches steel in strength while being 45% lighter. Its biocompatibility makes it ideal for surgical and orthopedic applications. Expanded titanium is highly sought after in military and defense, aerospace, automotive, electronics, and healthcare industries.

Process Details

In transforming metal sheets into expanded metal products, manufacturers begin with the expansion process. Following this, the sheets are shaped and formed to meet custom specifications. For a deeper understanding, continue reading.

1. The manufacturing process for regular and flattened metals begins in the same way. Initially, metal sheets are fed into a machine that presses and expands them. Nowadays, this procedure is typically managed by an automated system, ensuring greater efficiency.
2. After expansion, the die repeatedly pierces the sheet in a consistent pattern, typically creating a diamond shape. However, manufacturers also have the flexibility to cut and form custom shapes and patterns to meet specific requirements.
3. Next, manufacturers pass the sheet through a hot rolling press, causing the metal to expand, thin out, and flatten. If the original sheet is particularly thick, additional heat and pressure are applied to ensure proper expansion and cutting.
4. After this stage, manufacturers can enhance the expanded metal product through various finishing processes, such as annealing to boost corrosion resistance, applying veneers like paint or PVC, galvanization to create galvanized steel, or anodization. Protective coatings, applied either by spraying or dipping, are commonly used after the metal is formed. These coatings not only improve the metal’s properties but also allow manufacturers to alter the surface colors.
5. After this process, manufacturers regard the piece as a completed metal grid or mesh.

Design

When manufacturers engage in the expanding metal process, they must carefully consider several factors. Primarily, they need to determine the shape and size of the hole patterns in the expanded metal products according to the specific application requirements. They also need to take into account standard specifications, choose the most suitable metal based on its properties, select the appropriate metal gauge (thickness), and decide on the overall dimensions (length, width, etc.) and texture.

To determine the size of the open areas they plan to create during metal expansion, manufacturers use two measurement methods: SWD and LWD. SWD, or “short way of the diamond,” refers to the width of the openings. LWD, or “long way of the diamond,” indicates the length of the openings. These measurements are calculated based on the required density of air, water, or other substances that must pass through the metal pattern.

To tailor an expanded metal product, manufacturers can shape the metal to any specification and apply a variety of paints or coatings. They also have the flexibility to design custom hole patterns.

Machinery Used

Manufacturers utilize a variety of machines and tools to execute the metal expansion process and the subsequent parts forming procedure. This includes expansion presses, flattening presses, dies, and hot rolling presses.

Expansion presses work by pushing metal outward with a stretcher bar while cutting slits into the metal with mechanical knives. Manufacturers typically prefer automated CNC expansion presses over manual ones for their efficiency and precision.

Flattening presses live up to their name by flattening and smoothing metal sheets. They are used after perforation and expansion, working through cold rolling. In this process, parallel cylinders apply pressure to the metal as it moves between them, squeezing it into a smooth, even surface.

Dies are specialized manufacturing tools that work with presses and forming machines. Crafted primarily from metal, these tools are engineered to match the shape of the intended product. When material is fed through or pressed into the die, it is cut and shaped according to the die’s design.

Hot rolling presses are designed with rollers to flatten metal by working it at temperatures above its recrystallization point. This distinguishes them from cold rolling presses, which operate at lower temperatures.

Advantages over Similar Processes

Perforated metals and wire mesh are closely related to expanded metals. Perforated metals feature sheets with evenly spaced holes punched into them, while wire mesh is created from interwoven wires forming a grid pattern. Both materials, much like expanded metals, find application across diverse industries for tasks such as filtration, screening, fencing, and architectural design.

While each of the three processes has its own benefits, expanded metals stand out in particular scenarios. They are notably lighter than perforated metals, which simplifies handling and installation. The manufacturing process for expanded metals involves slitting and stretching a single sheet of metal to create a pattern of interlocked strands. This unique structure gives expanded metals added strength and rigidity, often making them more durable than perforated metals, especially in high-stress situations.

Expanded metals offer greater versatility and customization compared to wire mesh. Their openings and patterns can be adjusted to meet specific needs, allowing for a wide range of designs and functions. In contrast, wire mesh is constrained by the thickness and arrangement of its wires, limiting its customization options. Additionally, expanded metals provide improved visibility with more pronounced openings, making them ideal for applications requiring transparency, such as architectural facades and safety barriers.

They also offer the advantage of efficient material use. The manufacturing process involves stretching the metal rather than removing it, resulting in minimal waste. This approach not only leads to cost savings but also makes the production process more environmentally friendly compared to techniques that produce more scrap material.

In summary, although perforated metals and wire mesh excel in their respective applications, expanded metals provide distinct advantages that often make them the preferred choice. Their lightweight nature, inherent strength, and versatility offer exceptional durability and cost-effectiveness. Moreover, their efficient material usage and enhanced visibility make expanded metals superior to other products in specific contexts.

Benefits

Expanded metals offer numerous advantages, making them a popular choice in various industries. Their open design enhances ventilation and drainage, providing significant benefits. Whether used as grating in industrial environments, walkways, platforms, or as screens for air or liquid filtration, the interconnected pattern ensures efficient airflow and fluid passage. This feature is particularly valuable in applications where proper ventilation or drainage is crucial for optimal performance and safety.

They offer remarkable versatility, allowing for customization of opening sizes and shapes to suit diverse applications. Their adaptability makes them ideal for a range of uses, from architectural facades to automotive parts and concrete reinforcement. This flexibility ensures that expanded metals can meet a variety of design and functional requirements.

Additionally, expanded metals are low-maintenance due to their robust construction, which endures harsh environmental conditions. This makes them ideal for outdoor use where exposure to weather, moisture, or chemicals is common. Their minimal upkeep leads to lower costs and a longer product lifespan.

Moreover, expanded metals are environmentally friendly because their production process optimizes material use. The stretching technique generates minimal waste, leading to a reduced environmental impact compared to other manufacturing methods.

In summary, expanded metals offer significant advantages across various applications. Their superior ventilation and drainage properties, combined with their versatility and low maintenance needs, make them a practical and reliable choice. Additionally, their eco-friendly production process further enhances their appeal. These benefits position expanded metals as an excellent solution for diverse industries, including construction, architecture, filtration, automotive, and more.

Finding the Right Service Provider

Metal expansion isn’t overly complex, but the difference between an experienced service provider and a novice can be significant. For the best results, partnering with someone who has both extensive experience and a solid reputation is crucial. To assist you, we’ve compiled a list of our most trusted expanded metal suppliers. You can find their company information and profiles interspersed between the paragraphs above.

Before diving into your search, we recommend taking some time to compile a list of your own. Include all your specifications, questions, and concerns. Once your list is ready, use it as a guide during your search. Eliminate any company that doesn’t meet your requirements. Select three or four expanded metal manufacturers that catch your interest and reach out to them. Be sure to discuss your budget, timeline, and delivery preferences. After speaking with each, compare the responses to determine which manufacturer best suits your needs and move forward from there.