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In the world of screening and filtration, countless materials are at your disposal. Navigating through the fairly saturated market and pinpointing a solution is the key to operational success.
Now, as it delivers the ideal balance of versatility, functionality, and cost-effectiveness, wire mesh stands out as one of the more predominantly used screening materials. Crimped wire mesh and woven wire mesh are two wire mesh variants that each deliver unique benefits that make them ideal for specific applications.
Having said that, which one makes more sense for you?
W.S. Tyler has been dedicated to pioneering customer-centric woven wire innovation for over 150 years. We strive to provide you with a comprehensive understanding of what wire mesh solution makes the most sense for your operation.
And with that, we wrote the following article to compare and contrast crimped and woven wire mesh, offering insight into everything you need to know to make an informed decision. It will cover:
What crimped wire mesh is
What woven wire mesh is
How crimped wire mesh and woven wire mesh compare
Which wire mesh variant is best suited for you
What Is Crimped Wire Mesh?
Crimped wire mesh is best defined as a woven wire variant in which the individual wires of the weave are pre-crimped prior to the weaving process. Pre-crimping involves bending the wires in consistent, uniform zig-zag patterns.
Crimped wire mesh can be found in similar alloys as woven wire mesh, including stainless steel, alumunum, copper, etc. Additionally, crimped wires can be used to form various weave profiles, such as plain weaves, intermediate crimps, and flat-top crimps.
What Is Woven Wire Mesh?
Woven wire mesh is a metallic fabric constructed from hundreds of individual wires that are interwoven in an over-under orientation during a precise centuries-old weaving process. This leaves a wire mesh in which the wire wires are interlaced at right angles, creating pore openings that are both rigid and uniform.
Get to know how woven wire mesh is made in this step-by-step guide:
What makes woven wire mesh such a widely used material is the fact that virtually every parameter of the mesh can be tailored to your exact needs. This includes wire diameter, weave pattern, alloy, and mesh count.
What Are the Key Differences Between Crimped Wire Mesh and Woven Wire Mesh?
While they may look similar, crimped wire mesh and woven wire mesh have several manufacturing and structural differences that you should be mindful of.
Looking at how it's made, crimped wire mesh requires a pre-crimping process that physically bends and alters the profile of the individual wires. This pre-crimping creates a more stable and rigid weave in which the wires are held in place better.
These crimps create a textured surface. But at the same time, helps maintain the shape of the mesh as well as the spacing of the openings.
That said, the crimped wire mesh renders the material more suitable for heavy-duty applications that subject the mesh to high levels of mechanical stress.
Woven wire, on the other hand, interlaces the wires of the weave at right angles and does not require the wires to be processed before the weaving process. The lack of crimping often results in a smoother surface.
While not as rigid, woven wire mesh is considerably more flexible and easier to form. This flexibility is, of course, heavily influenced by the wire diameter and weave pattern.
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Crimped Wire Mesh or Woven Wire Mesh: Which Should I Use?
Choosing between the two mesh variants should be determined by the specific needs of your application.
Applications that require stronger, more robust weaves should rely on crimped wire mesh. Applications that require fine precision and increased flexibility must use woven wire mesh.
With its superior rigidity, crimped wire mesh is more likely to be used for screening in the mining, construction, and other heavy-duty industries. But as it is more flexible and often delivers finer specifications, woven wire mesh is typically seen in filtration and sieving applications.
Get To Know What Wire Mesh Is Right for You
Crimped wire mesh and women's wire mesh are both wire mesh variants designed to accommodate specific screening/filtration applications. Crimped wire mesh is best suited for heavy-duty industrial applications, whereas woven wire is widely used to deliver accurate separation of finer particles.
But it is important that you understand all the wire mesh variants available to you, including welded wire mesh. This knowledge will allow you to construct and implement the perfect solution and generate the results you need to succeed.
With over 150 years of wire mesh experience under our belts, W.S. Tyler is here to create a cleaner, safer world through methodically crafted wire mesh solutions.
To learn more about welded wire mesh and how it gits your process, read the following article:
To facilitate the centuries-old weaving process, wire mesh suppliers must employ specialized weaving looms designed to work with metallic wires. These looms consist of seven components: a warp beam, warp wires, heddle frames, weft wires, a rapier band, a reed, and a front take-up mechanism.
The warp beam is a cylindrical beam that is used to wind the warp wire after the volume and length of the wires are calculated based on the specifications of the mesh.
Warp wires are the wires that run vertically and are threaded through the entire loom.
The heddle frames are holsters that are used to organize and separate the warp wires. Looms set up to produce a square mesh may have two sets of heddle frames, whereas more complex filter cloth weaves may have more.
Weft wires are the wires the run horizontally and are typically fed by a separate spool of wire.
The rapier band system is responsible for threading the weft wire through the sets of warp wires between heddle frame movements.
The reed is one of the most essential elements of a weaving loom as it is used to position the warp wires they will be woven in and drive the weft wires into their exact potion.
The front take-up mechanism rolls the woven mesh once it is fully woven.
The Weaving Process
To initiate the weaving process, a loom operator will attach and arrange the individual wires on the warp according to their position in the weave. To prevent entanglement, these wires are housed in a wire housing unit known as a creel.
Once attached, the warp beam is wound, allowing the proper length of wire to be wrapped around the beam.
Each wire wound on the warp beam is threaded through its own heddle in a specific heddle frame then carefully threaded through the reed openings based on their order in the weave. At this point, the warp beam, heddle frame assembly are transferred to the weaving hall, and the remainder of the loom is assembled.
NOTE: A great deal of attention to detail must be applied when threading the wire through the heddle frames and reed, as this process control how accurate the mesh specifications are.
Once the loom is fully assembled and the wires are properly threaded, the weaving process can begin.
When first initializing the weaving loom, the warp beam unwinds slightly to feed a small increment of wires. At the same time, the front take-up mechanism winds the same increment of wires to maintain the required tension to produce high-quality mesh.
Once these movements are made in conjunction, the heddle frames shift to separate the wires. In a two-heddle frame system, the first heddle frame lifts one half of the wires, and the second heddle frame drives the other half of wires down.
While the two sets of wires are separated, a weft wire, typically fed from a wire spool that is separated from the creel and placed next to the loom, is shot between the wires by the rapier band. The rapier band then moves back to its resting position.
It's at this point that the reed propels the weft wire to its final position, creating the precise cross-sections that wire mesh is known for. Once the weft wire is positioned, the reed returns to its resting position.
This marks the completion of the first interval.
To continue the weaving process, the warp beam and front take-up mechanism make the same slight, rotating movement to begin another interval. At the same time, the heddle frames will switch potion, wedging the previous weft wire as the two sets of wires are separated in the opposite direction.
These joint movements repeatedly continue until the desired length and mesh specification is woven.
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