What materials is battery mesh made from?

Battery mesh is most commonly made from commercially pure nickel (Nickel 200 / N02200 and low-carbon Nickel 201 / N02201), titanium, copper, or stainless steel 304/316. The material is chosen by cell chemistry, conductivity, corrosion environment, and cost: nickel for alkaline cells, titanium for corrosive or chloride electrolysis, copper for maximum conductivity, and stainless for economical supports.

What is nickel mesh used for in batteries?

Nickel mesh is used as the positive current collector in nickel-metal hydride (Ni-MH) and nickel-cadmium (Ni-Cd) cells, as an electrode substrate in lithium-ion research and production hardware, and as a conductive support in supercapacitor and fuel cell electrodes. Its corrosion resistance in alkaline electrolyte is a key reason for its use.

What is the difference between Nickel 200 and Nickel 201 mesh?

Nickel 200 (UNS N02200) has a 0.15% carbon maximum; Nickel 201 (UNS N02201) has a 0.02% carbon maximum. Nickel 201 is preferred for prolonged service above 315°C / 600°F because its lower carbon content reduces graphitization risk. Below that threshold, Nickel 200 is normally selected when its other properties suit the duty.

Is copper mesh used in batteries?

Yes. Copper mesh is used for conductive current collectors, busbars, and low-resistance contact mesh where maximum conductivity matters, for example in lithium-ion current collection. Copper oxidizes more readily in some environments, so state the purity (for example C11000) and any oxidation or coating concern in the RFQ.

Is titanium mesh used in batteries?

Yes. Titanium mesh is chosen where corrosion resistance dominates, such as electrolysis electrodes and coated-anode substrates in chloride and acidic media. It is lightweight and stable under anodic potential, and it is commonly supplied with MMO or RuO2 catalytic coatings for oxygen and hydrogen evolution.

What is the difference between battery mesh and nickel foam?

Battery mesh is a woven, expanded, perforated, or electroformed metal structure with defined openings and controlled geometry. Nickel foam is a three-dimensional porous metal with high porosity and a sponge-like structure. They serve different electrode roles: mesh provides a defined, rigid conductive substrate, while foam offers very high surface area. Confirm the structure your electrode build requires.

What mesh count and wire diameter are typical for battery electrodes?

Typical values depend on the duty. The current Pure Nickel catalog reference lists 40 mesh with 0.25 mm wire and 80 mesh with 0.12 mm wire, but battery mesh ranges more widely by application and material. State the mesh count, wire diameter, aperture, open area, and tolerance in the RFQ so the geometry is defined rather than assumed.

Expanded or woven battery mesh?

Woven mesh has defined square apertures, is flexible, and suits electrode substrates where controlled opening and flex matter. Expanded mesh is slit-and-stretched foil with diamond openings, is thin and lightweight, and suits current collectors where low resistance per unit weight is required. Match the form to the electrode build and current-distribution needs.

What is electroformed mesh used for?

Electroformed mesh is made by electrodeposition and has uniform fine pores with high precision. It is chosen for precision current collectors and electrode structures where uniform current distribution is critical, and it is also documented for electroformed nickel foil in technical literature.

What is the typical MOQ and lead time?

Stock mesh counts and standard forms start from low minimums and often ship within 7-15 days. Custom geometries, foil-thin expanded mesh, or coated anodes carry higher minimums and typically need 2-4 weeks. Share your full specification and target date for a confirmed schedule.

Do you provide certificates and samples?

Yes. Material test certificates and dimensional inspection reports are available, and pre-shipment inspection by SGS, BV, or TÜV can be arranged with the report shared before dispatch. Request a sample of the exact grade, mesh geometry, and form to confirm finish and quality before bulk production.

What affects the price of battery mesh?

Several factors move the quote. Material grade and purity set the base metal cost, with nickel, titanium, and copper priced above stainless. Mesh geometry and form determine processing difficulty: foil-thin expanded and electroformed mesh cost more to produce. Surface treatments such as RuO2 or MMO coatings add cost, and quantity, processing, and destination affect production and freight per unit. Share the full specification and target date for an itemized, current quote.

Application-led electrode and current collector mesh sourcing for battery engineers and procurement

Battery Mesh: Nickel, Titanium & Copper Electrode and Current Collector Mesh

Source battery mesh for electrodes and current collectors in nickel, titanium, copper, and stainless steel, in woven, expanded, perforated, and electroformed forms. Compare materials, mesh geometry, and sourcing details, then request a factory quote.

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View Specifications

N02200 / N02201Commercially pure nickel in Nickel 200 / N02200 and low-carbon Nickel 201 / N02201 grades for electrode and collector duty

4 Forms x 4 MaterialsWoven, expanded, perforated, and electroformed mesh routes across nickel, titanium, copper, and stainless steel

Specify Before PricingBattery mesh is priced accurately when the RFQ states chemistry, mesh geometry, form, processing, quantity, and destination

Specifications and standards

Battery Mesh Specifications

Battery mesh is defined by material grade, mesh geometry, form, finish, and processing together. Mesh count alone does not define performance. For industrial woven wire cloth, ASTM E2016 and ISO 9044 provide useful terminology and tolerance references.

Material routes

Nickel (N02200/N02201), titanium, copper, or stainless steel 304/316, chosen by cell chemistry, conductivity, corrosion environment, and cost

Nickel grades

Nickel 200 (UNS N02200, 0.15% carbon max) and low-carbon Nickel 201 (UNS N02201, 0.02% carbon max, preferred above 315°C / 600°F); current catalog reference 40 and 80 mesh

Mesh geometry

Mesh count per linear inch, wire diameter, aperture, open area, and tolerance. Mesh count alone does not define the opening; state the full geometry

Form

Woven, expanded (diamond), perforated, or electroformed; each changes thickness, rigidity, surface area, and current distribution

Finish and processing

Slitting, cutting, tab or welding compatibility, and surface treatments such as acid washing, polishing, or RuO2 / MMO catalytic coatings for coated anodes

Verification

Material test certificates and dimensional checks per the agreed geometry; composition screening by XRF is limited where carbon content distinguishes the grade

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Material route	Typical battery role	Why it is used	RFQ note
Nickel	Ni-MH / Ni-Cd positive collectors, Li-ion and supercapacitor electrode substrates	High conductivity, corrosion resistance in alkaline electrolyte, ductile and weldable	State N02200 or N02201 grade, mesh geometry, and any finish. Catalog reference: 40 and 80 mesh
Titanium	Electrolysis and coated-anode substrates, corrosion-resistant collectors	Outstanding corrosion resistance in chloride and acidic media, lightweight, stable under anodic potential	Confirm grade, mesh geometry, and any MMO or RuO2 coating requirement
Copper	Conductive current collectors, busbars, and low-resistance contact mesh	Highest electrical conductivity and low contact resistance	State purity (for example C11000), thickness, and any oxidation or coating concern
Stainless steel (304/316)	Economical electrode supports and structural mesh in mild or alkaline duty	Strength, corrosion resistance, and lower cost at production scale	Confirm alloy, surface finish, and the electrolyte environment

Battery Mesh Forms Compared

The form changes how the mesh behaves as an electrode or collector. Match the form to the electrode build and the current-distribution requirement.

Form	How it is made	Structure	Typical battery use
Woven mesh	Interlaced wire in plain, twill, or Dutch weave	Defined square apertures; flexible, tailorable open area	Electrode substrates and support screens where controlled opening and flexibility matter
Expanded mesh	Slit-and-stretched foil or sheet	Diamond openings; thin, lightweight, stiff strands	Current collectors where low weight and low resistance are required
Perforated mesh / grids	Punched or stamped sheet	Round or shaped holes; rigid, plate-like structure	Rigid electrode grids and plate-supported collectors
Electroformed mesh	Electrodeposited nickel	Uniform fine pores with high precision	Precision current collectors where uniform current distribution is critical

Nickel Mesh Geometry Reference (Catalog)

These values come from the current Pure Nickel catalog product record. They are reference points, not a stock or lead-time promise; confirm the final grade, weave, dimensions, tolerances, and quantity in the RFQ.

	Mesh count	Wire diameter (mm)	Aperture (mm)	Open area	Listed weight (kg/m²)
	40 mesh	0.25	0.385	36.8%	1.25
	80 mesh	0.12	0.198	38.8%	0.58

Battery Mesh RFQ Checklist

Providing these fields lets the sourcing and factory teams evaluate a comparable requirement instead of quoting against an incomplete mesh description.

Field	What to state	Why it matters
Cell chemistry and duty	Li-ion, Ni-MH, Ni-Cd, supercapacitor, fuel cell, or electrolyzer; electrolyte, temperature, current loading	Drives material grade and mesh geometry together
Material	Nickel 200 / N02200, Nickel 201 / N02201, titanium, copper, or stainless grade	Prevents a purity or grade assumption
Geometry	Mesh count, wire diameter, aperture, open area, and tolerance	Defines electrical and mechanical behavior together
Form and finish	Woven, expanded, perforated, or electroformed; surface treatment	Sets thickness, rigidity, and coating compatibility
Processing	Roll or sheet, width, slitting, cutting, tab or welding detail	Determines fabricability and lead time
Acceptance	MTC, dimensional checks, sample need, quantity, destination, required date	Aligns documentation, inspection, logistics, and quotation basis

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Available forms

Battery Mesh Forms We Source

Four forms are available across nickel, titanium, copper, and stainless steel. Compare thickness, rigidity, and current distribution before you specify.

Woven battery mesh

Plain, twill, or Dutch woven cloth in nickel, copper, stainless, or titanium with defined square apertures; the flexible, tailorable route for electrode substrates.

Expanded battery mesh

Slit-and-stretched foil producing diamond openings; thin and lightweight, used for current collectors where low resistance per unit weight matters.

Perforated battery mesh

Punched sheet with round or shaped holes; a rigid, plate-like structure for electrode grids and plate-supported collectors.

Electroformed battery mesh

Nickel mesh made by electrodeposition with uniform fine pores and high precision, chosen where uniform current distribution is critical.

How to choose

How to Select the Right Battery Mesh

Start from the cell chemistry, then fix material grade, mesh geometry, form, finish, and processing. A complete battery mesh RFQ avoids assumptions and re-quotes.

Start from the cell chemistry

Li-ion, Ni-MH, Ni-Cd, supercapacitor, fuel cell, and electrolyzer each place different demands on conductivity, corrosion resistance, and porosity. Name the chemistry first.

Choose the material grade

Nickel for alkaline cells, titanium for corrosive or chloride electrolysis, copper for maximum conductivity, stainless for economical supports.

Define mesh geometry

Mesh count, wire diameter, aperture, and open area together determine electrical and mechanical behavior; mesh count alone is not enough.

Select the form

Woven, expanded, perforated, and electroformed forms change thickness, rigidity, surface area, and current distribution. Match the form to the electrode build.

Confirm surface treatment

Acid washing, polishing, or catalytic coatings such as RuO2 or MMO change electrochemical behavior and are specified for coated anodes.

Plan processing

Slitting, cutting, tab welding, and roll versus sheet supply affect yield, lead time, and assembly fit.

State duty and qualification

Electrolyte, temperature, current loading, and any qualification tests keep the RFQ comparable and prevent re-quotes.

Give quantity and destination

Quantity, destination port, and trade terms let the factory price material, processing, and freight accurately.

Buyer benefits

Why Buyers Choose Battery Mesh

Battery mesh earns its place in electrode assemblies for verifiable reasons: it conducts, it supports active material, and it can be matched to the electrochemistry.

Conductive electrode support

Metal mesh conducts current across the electrode while supporting active material, reducing internal resistance and improving current distribution.

Corrosion-matched routes

Nickel, titanium, copper, and stainless options let the mesh match the electrolyte and operating temperature.

Controlled open area

Aperture and open area are specifiable, supporting active-material loading and electrolyte penetration where the duty requires it.

Four forms, one sourcing route

Woven, expanded, perforated, and electroformed mesh are sourced through one RFQ with matched quality control.

Fabrication-ready supply

Slitting, cutting, and welding-compatible supply formats fit electrode assembly lines.

Specification-led QC and traceability

Material test certificates, dimensional checks, and labeled lots give traceable, inspectable supply.

Applications

Where Battery Mesh Is Used

Battery mesh serves as a conductive electrode substrate or current collector wherever a metal mesh must carry current and support active material. Confirm the electrochemistry and duty in the RFQ.

Lithium-ion current collectors

Nickel or copper mesh used as a current collector or electrode substrate in Li-ion cells and research hardware, improving contact between active material and electrolyte and distributing current across the electrode.

Nickel-metal hydride (Ni-MH) electrodes

Nickel mesh serves as the positive current collector in Ni-MH cells, supporting active material while conducting current under repeated charge-discharge.

Nickel-cadmium (Ni-Cd) electrodes

Nickel mesh is used as a current collector in Ni-Cd electrode assemblies where corrosion resistance in alkaline electrolyte and high-rate discharge matter.

Supercapacitor electrodes

A conductive, high-surface-area mesh substrate for supercapacitor electrodes, supporting active-material loading and fast charge-discharge.

Fuel cell components

Mesh electrode or gas-diffusion support in fuel cells, where conductivity and controlled porosity support gas and charge transport.

Water electrolysis and hydrogen

Nickel or titanium mesh electrodes and coated anodes in alkaline and PEM electrolysis, with catalytic coatings applied for oxygen and hydrogen evolution.

Common buying mistakes

Battery Mesh Buying Mistakes to Avoid

Six errors that lead to the wrong mesh, delayed delivery, or an uncomparable quote. Every one is avoidable at the RFQ stage.

Specifying mesh count alone

Mesh count without wire diameter does not define the opening. State count, wire diameter, aperture, and open area.

Confusing Nickel 200 and 201

Nickel 201 has a lower carbon limit and is preferred for prolonged service above 315°C / 600°F. Name the grade in the RFQ.

Choosing material by name, not environment

The electrolyte and operating temperature decide whether nickel, titanium, copper, or stainless suits the duty, not the material name alone.

Overlooking form fit

Woven mesh flexes while expanded mesh is stiffer, and electroformed mesh carries the tightest tolerances. The electrode build determines which form fits.

Ignoring processing tolerance

Slitting and cutting tolerances, roll width, and flatness affect electrode assembly. State them to avoid rejects at your line.

Leaving out duty and qualification details

Current loading, temperature, electrolyte, and test requirements belong in the RFQ to avoid an uncomparable quote and a second round of pricing.

Battery mesh is supplied as rolls or sheets and finished into electrode parts with clean cutting, matched joining, and the specified surface treatment.

Processing and handling

From Battery Mesh to Electrode Part

Confirm roll dimensions and slitting

State roll width and required strip width so the factory slits cleanly with minimal waste and consistent edge condition.

Cut to electrode size with clean edges

Cut mesh to the electrode footprint with burr-free edges to avoid shorting, coating defects, and handling damage.

Prepare for tab and weld joints

Confirm the tab material and joining method. Nickel and copper mesh weld and solder with matched filler; titanium needs specialist joining.

Apply surface treatment before coating

Acid washing, polishing, or catalytic coating is applied before active-material coating, as specified in the RFQ.

Packing and delivery

Battery Mesh Packing for Export

Packing keeps mesh flat and clean, protects foil-thin forms from edge damage, and preserves traceability through transit and receiving inspection.

Rolls and sheets protected

Mesh is wrapped and edge-protected to avoid deformation, scratching, and burring in transit.

Palletized for container loading

Packed to the container plan with edge protection against forklift and handling damage.

Label by specification

Each lot carries grade, mesh geometry, form, dimensions, quantity, and production lot for traceability.

Certificates on request

Material test certificates and dimensional inspection reports accompany the shipment when ordered.

Share destination details

State destination port, trade term, and inspection requirements. Pre-shipment inspection by SGS, BV, or TÜV is available on request.

Factory QC before shipment

Incoming wire, weaving or forming, finishing, and final inspection with AQL sampling happen before dispatch.

Typical use scenes

Battery Mesh in Service

Use scenarios show how material, geometry, and form change by duty; they are not customer claims.

Battery electrode substrate

Nickel mesh in 40-80 mesh woven cloth specified as an electrode substrate for alkaline battery research and qualification hardware.

Electrolysis test hardware

Nickel or titanium mesh electrodes configured for electrolysis and hydrogen test rigs, with coated-anode options.

Electronics and precision collectors

Conductive nickel mesh in electronic and vacuum components where controlled conductivity and low gas content matter.

Conductive copper mesh assemblies

Copper mesh specified for current collection and shielding test assemblies where maximum conductivity is required.

Products and resources

Battery Mesh Sourcing Resources

Compare the material grades, product catalog entries, and related categories. Confirm the standard edition and your electrochemistry before ordering.

Last updated: 2026-09-18

Nickel wire mesh materialNickel 200 and 201 grades, catalog reference, and RFQ details.Copper wire mesh materialConductive copper mesh for current collection and shielding.Stainless steel wire mesh material304/316 stainless routes for economical electrode supports.Woven wire mesh categoryWoven mesh types, weaves, and specifications.Expanded wire mesh categoryExpanded metal mesh for lightweight current-collector routes.Browse the wire mesh catalogCompare types, materials, and specifications by SKU.

Reference standards

ASTM E2016Standard specification for industrial woven wire cloth.ISO 9044:2016Industrial woven wire cloth — technical requirements and tests.Special Metals electroformed nickel foilTechnical bulletin on electroformed nickel foil for precision electrode structures.

FAQ

Battery Mesh FAQ

Common procurement questions about materials, mesh geometry, forms, and ordering battery mesh.

Battery mesh is a metal mesh used as an electrode substrate or current collector in batteries and electrochemical devices. It is most commonly made from nickel, titanium, copper, or stainless steel in woven, expanded, perforated, or electroformed form, and it conducts current across the electrode while supporting active material.

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Send your cell chemistry, material grade, mesh geometry, form, quantity, and destination. Our sourcing team replies with a specification-led review.

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Send cell chemistry, material grade, mesh geometry, form and finish, processing needs, quantity, and destination for a specification-led sourcing review. Our team replies with matched battery mesh options and a factory quote.