Metal Mesh Foil

Metal mesh foils are conductive, porous metal substrates supplied as mesh sheets or rolls, commonly used in battery testing and electrochemistry. Compared with solid foils, a mesh structure provides open pathways for electrolyte penetration and gas transport, while still offering a low-resistance electron conduction network. This makes mesh foils useful as current collectors, mechanical supports for coated layers, and flow-permeable electrode scaffolds in research cells.

Materials and selection guide

ScienceGears can supply metal mesh foils in three common materials:

• Aluminium (Al) mesh: lightweight conductive substrate used in general electrode prototyping where aluminium is compatible with the electrolyte and potential window.

• Copper (Cu) mesh: high-conductivity mesh commonly used as an anode-side current collector or porous support in battery R&D and electrochemical testing.

• Nickel (Ni) mesh: mechanically robust porous substrate widely used in alkaline electrochemistry, electrocatalysis, and hydrogen-related research, supporting efficient bubble release and mass transport.
  
  

Key features

• Porous mesh architecture for improved wetting and transport
• Available in sheets or rolls; cut-to-size options for coin/pouch/custom cells
• Mesh parameters (opening, wire diameter, open area) can be selected to balance strength and permeability
• Suitable for clamping, tabbing, and catalyst/slurry coating workflows (process dependent)
  
  

Typical applications

• Battery electrode prototyping and structured electrodes
• Electrocatalysis screening and durability testing
• Alkaline and hydrogen research requiring porous current-carrying supports

ScienceGears supports researchers across Australia and New Zealand with mesh selection guidance and compatibility with potentiostats/galvanostats, battery cyclers, and electrochemical cell hardware.