Have you ever seen a sheet of expanded metal and wondered: How do they make expanded metal? These metal meshes look so strong yet lightweight. In this article, we’ll walk through the basics of expanded metal mesh production, different types, and how they are used. And once you understand the process, you may also want to learn how to measure expanded metal correctly, since sizing plays a big role in choosing the right type for your project. Let’s go!
What is Expanded Metal?
Expanded metal is a single sheet of metal that has been slit and stretched to create a mesh of diamond-shaped openings. Unlike welded or woven mesh, it remains one continuous piece. Because no material is lost during the process, expanded metal is also a more eco-friendly alternative to perforated sheets, which generate scrap material that requires disposal. While diamond shapes are most common, other patterns or designs can also be created for different uses.
Benefits of Expanded Metal Sheet
- Cost-Effectiveness: With zero material waste, producing expanded metal has lower raw material costs. A single sheet can be stretched to cover a much larger area, making it more economical than other options.
- Durability: Because it’s made from one continuous piece, expanded metal is stronger than wire mesh or welded strands. Its interconnected structure spreads weight evenly and resists stress, making it ideal for heavy-duty applications.
- Permeability: The uniform openings allow air, light, heat, sound, and liquids to pass through freely. Mesh size and shape can be adjusted, making it useful for ventilation, filtering, and even light regulation.
- Slip Resistance: The raised diamond pattern provides natural anti-slip properties. Its angled strands and uncut knuckles give a better grip underfoot, making it a safe choice for walkways and platforms.
- Lightweight: Even though it’s strong, expanded metal is surprisingly light, offering an excellent strength-to-weight ratio. Since a sheet can be expanded up to ten times its original width, it reduces overall weight while still maintaining rigidity, perfect for structures where load reduction is important.
From industrial flooring and machine guards to decorative facades and ventilation screens, expanded metal is valued for its balance of performance, efficiency, and design potential.
Expanded Metal Manufacturing Process
Now, let’s get into the details of how expanded metal is made.
Selecting the Metal
Choosing the right material is the first step, since each one offers different benefits. Common options include stainless steel, hot or cold rolled steel, aluminum, carbon steel, copper, brass, galvanized steel, nickel, titanium, and even plastics or vinyl sheets. For most projects, carbon steel is normally the go-to choice thanks to its strength and cost-effectiveness.
Feeding the Metal
Once the sheet or coil is ready, it’s fed into an expanding metal mesh machine. This machine is fitted with knives or dies made of upper and lower blades. These blades are what decide the shape and size of the mesh openings.
Slitting and Stretching
The real magic happens here. The knives make alternating cuts in a uniform pattern. As the sheet moves forward, the machine pushes down on the freshly cut sections, stretching them apart into long “ribbons.”
These ribbons stay connected to the uncut areas of the sheet, which form the corners of the diamond-shaped openings you see in the mesh. Adjustments in blade position, sheet thickness, and machine settings allow manufacturers to create many different opening sizes and shapes.
Pattern Formation
As the sheet is slit and stretched, it takes on its final and signature look: rows of diamonds (or other patterns, depending on the setup). These openings aren’t just for appearance. The three-dimensional raised structure adds strength, rigidity, and slip resistance, making it useful for everything from walkways to machine guards.
Roll Flattening (Optional)
Sometimes, a smooth finish is better. In those cases, the raised mesh goes through a cold rolling process. This step flattens the diamonds into a thinner, smoother surface. It also makes the sheet longer and slightly lighter while reducing the size of the openings.
Final Product
After the expanding (and flattening, if needed), the mesh is either cut into sheets or rolled into coils. And since it’s made from one continuous sheet without welding, expanded metal won’t unravel even if it’s cut.
Types of Expanded Metal
Expanded metal isn’t just one product—it comes in several types, each with its own strengths and uses. The differences come from the way it’s made or the design of its openings.
Standard Expanded Metal
This is the classic type, made straight from the expanding machine. It has a raised, three-dimensional surface with diamond-shaped openings. The angled strands make it strong, rigid, and naturally slip-resistant while still letting air and light pass through. It’s affordable, versatile, and available in many sizes, which is why it’s the most commonly used type.
Flattened Expanded Metal
When standard expanded metal is put through a cold rolling process, the raised diamonds are pressed flat. The result is a smoother, thinner, and sometimes longer sheet. It’s not as grippy as raised metal, but it looks cleaner and is easier to work with in decorative projects. Think of it as the sleek version of expanded metal.
Hexagonal Expanded Metal
Instead of diamonds, this version features hexagon-shaped openings. The shape adds strength and still allows air, heat, sound, and liquids to pass through. It’s often chosen when the metal is expanded more heavily.
Architectural Expanded Metal
This type focuses on looks as much as function. It may still use diamond openings, but often includes unique designs that architects love for facades, screens, and interiors. The sheets are usually thinner, allowing for more intricate details, while still offering privacy, ventilation, and security.
Micro Expanded Metal
Made from thin-gauge metal with tiny openings, micro expanded metal is ideal for filters or situations where small particles need to be kept out. The openings can be diamond, hexagonal, square, or flattened, depending on the need.
Expanded Metal Grating
First, we need to clarify that mesh is a broad term that covers everything from fine, decorative sheets to tougher industrial options. Grating, on the other hand, is the heavy-duty version, built for strength and durability.
Expanded metal grating uses thicker metal and larger openings, making it ideal for load-bearing applications in high-traffic settings, such as platforms, walkways, and stair treads. Because it’s formed from a single solid sheet without welds or joints, it delivers excellent strength-to-weight performance and natural slip resistance.
Uses of Expanded Metal Mesh
Expanded metal mesh is one of the most versatile materials you’ll find, used across countless industries. Let’s take a closer look at some of the most common applications.
Filtration Systems
Expanded metal is a reliable choice for filtration. Its uniform openings allow air, light, heat, sound, and liquids to pass through while blocking larger particles. This makes it effective in air and fluid filters, balancing flow with protection and ensuring efficient ventilation.
Security and Protection
Security is one of the strongest suits of expanded metal. Because it is made from a single piece, it won’t unravel and provides durable protection. It is widely used for fences, gates, and guardrails around warehouses, highways, and private properties. In industrial facilities, expanded metal serves as machine guards and barriers to protect workers.
It is also used for window security screens, covers for appliances like air conditioners, and cages or enclosures for storage and animal housing. In some cases, expanded metal baskets are built into fire safes to protect delicate items during a fire.
Walkways, Platforms, and Grating
For areas that require strength and safety, expanded metal grating is an excellent option. Its slip-resistant surface makes it ideal for walkways, stairs, and platforms in industrial settings. You’ll also find it on catwalks along billboards or inside factories. Thanks to its durability and anti-slip qualities, it is a trusted flooring material for busy industrial and commercial areas.
Automotive and Transportation
In the automotive and transport industries, expanded metal is used in vehicle components and infrastructure. It strengthens roadside barriers and protective structures while remaining lightweight. Its combination of durability and efficiency makes it suitable for cars, roads, and side road protection.
Architectural and Decorative Design
Expanded metal is not just about function—it’s also valued for design. Architects use it for facades, cladding, and sun breakers to improve ventilation and shading while enhancing building aesthetics. Indoors, it can be found in suspended ceilings, ceiling tiles, decorative screens, and partitions. Even balustrades and railings often use expanded metal to combine safety with a modern look.
Electronics and Communications
Electronics is another field where expanded metal plays a big role. It is used in battery cells, speaker covers, radar and satellite antennas, and EMI shielding for electronic devices. Its durability makes it a dependable component in electric instruments and appliances.
Everyday Uses
Beyond these industries, expanded metal shows up in many other places. Public benches, outdoor grills, and heavy-duty shelving often use it for strength and ventilation. In construction, it helps reinforce concrete, while its thermal properties make it useful in insulation panels. Manufacturing plants also rely on expanded metal baskets for washing, degreasing, or organizing heavy parts while maintaining airflow.
KEN GI is Your Trusted Partner in Expanded Metal Manufacturing
Expanded metal has proven to be one of the most versatile materials in construction and design. From filters in HVAC systems to walkway panels for flooring and safety, it delivers durability and practicality. Choosing the right partner among global expanded metal suppliers ensures you receive products and support tailored to your project needs.
With over 40 years of experience, KEN GI stands as a trusted name in expanded metal manufacturing and machines. Our comprehensive service process covers everything from material selection, custom design, and production, to reliable delivery and after-sales support. Whether you need standard mesh, rib lath, diamond plate sheets, or other expanded metal mesh, we offer solutions built for performance and long-term value. For inquiries or custom requests, don’t hesitate to contact us today and experience the quality difference with KEN GI.