Wire Mesh Filters Overview

Wire mesh filters stand out for their durability, efficiency, and versatility in filtration. Whether you’re dealing with air or fluid filtration, these metal mesh filters offer superior performance compared to traditional options. The robust construction of wire mesh filter elements ensures long-lasting use, even in the most demanding environments.

a collage of many different filters in varying sizes

Fiberglass Versus All-Metal Filters – What The Research Shows

Recent commercial and military aviation research has explored the effectiveness of woven metal mesh filters and sintered metal filter media against conventional fiberglass filters. The findings indicate that wire mesh filters and various sintered metal filter media provide better resilience and filtration consistency under extreme conditions. Unlike fiberglass filters, which can degrade over time, metal mesh filters deliver high filtration capacity without compromising on durability, making them a superior choice for many applications.

1.      Metal Fiber Filters Dramatically Reduce Maintenance Versus Glass Fiber

The AED reported a remarkable reduction of maintenance—by 10 times—on six components in a 36,000-hour test on 120 helicopters with the use of metal mesh filters versus fiberglass. This data came from comparing the number of equipment failures in the hydraulic pump, primary servo, SAS actuators (for pitch trim, roll, and yaw boost), and the tail rotor servo. With wire mesh filters, failure rates dropped by an impressive 88%-92% across all components. These results showcase the superior durability and performance of metal mesh filters in rigorous applications, significantly reducing costly downtime.

2.      Metal Fiber Filters Produce Enormous Cost Savings Opportunities

The cost savings associated with the massive reduction in maintenance time achieved by metal mesh filters are substantial. According to the US AED, wire mesh filters can save approximately $4 million for every 100 hours of flight time in a fleet of 2,000 helicopters. This dramatic saving primarily results from the longer lifespan and reduced need for replacing hydraulic pumps and primary servo components. The maintenance burden is significantly lowered with metal mesh filter elements, making them a highly cost-effective solution for aviation and beyond. Cost- and time-saving measures can help with overall efficiency.

3.      All-Metal Filters Dramatically Reduce Contamination In Hydraulic Systems

Unlike fiberglass, wire mesh filters do not shed particles back into the hydraulic system, preventing further fluid contamination and significantly cutting maintenance time and costs. Early tests in commercial aircraft revealed that metal mesh filters reduced contamination by as much as 95%, which is significant when the smallest holdups can cost thousands. This contamination reduction is a game-changer, providing cleaner systems, longer component life, and reduced wear and tear. Organizations can enjoy reduced maintenance schedules with metal mesh filters while ensuring optimal system performance.

Bottom Line: All-Metal Filters Outperform Fiberglass In Aviation Applications

The results from this testing have been impressive and extremely gratifying for metal filter manufacturers and suppliers like us here at Fluid Conditioning Products (FCP).

While we also produce a limited selection of disposable filter elements for various applications utilizing legacy materials such as cellulose, paper, spun polyester, and fiberglass, these are not our primary focus. We are especially proud to be known for our all-metal, corrosion-resistant wire mesh filters made from stainless steel, nickel-copper, brass, and bronze.

In both US Army testing in Blackhawk, Apache, Kiowa, and other helicopters, and commercial airline testing in Boeing 737 jets, all-metal filters have been proven to reduce contamination in hydraulic systems and cut maintenance on a variety of other components.

In the future, it’s becoming clear that all-metal filters should be considered the standard in the aerospace and defense industries. Today’s blog post highlights three big outcomes from testing of all-metal filters that prove this assertion.

Testing In Army Helicopters Shows Excellent Results

In recent years, various all-metal filter manufacturers and suppliers submitted products for real-world (as opposed to traditional laboratory) testing to the US Army Aviation Engineering Directorate (AED). The AED had put a testing program in place to determine ways to improve the cleanliness of the hydraulic systems in several helicopter models.

Our friends at Baekert published a white paper to share some of the test case results with a metal fiber filter media that they submitted, and the results are excellent.

All-Metal Filters Present Opportunities That Are More Important Now Than Ever

While the aerospace and defense industries have shown resilience and growth in recent years, the landscape continues to evolve rapidly. In light of recent global challenges, commercial aircraft manufacturers are under increasing pressure to find cost-effective solutions without compromising performance and safety.

Commercial aircraft manufacturers are especially now looking for cost savings anywhere they can. Luckily, all-metal filters present some fantastic opportunities that we covered here today, specifically related to the maintenance of aircraft hydraulic systems.

Testing in Commercial Aircraft Is Also Promising For All-Metal Filters

While not reported in Baekert’s white paper, all-metal filters are also being tested as replacements for fiberglass filter media in commercial aircraft, including the popular Boeing 737 used by Southwest Airlines.


Commercial aircraft have many other filtration components that can also potentially be shifted to all-metal filter designs in the future. The benefits of fiberglass filters in these uses include superior cleanliness with no particle shedding, the ability to dissipate static charges, and an overall compact filter design.

Have an All-Metal Filter Project On The Horizon?

Whether you’re preparing for a new aerospace venture or seeking to enhance your existing systems, Fluid Conditioning Products is here to offer precision-engineered wire mesh filters and metal mesh filters. Our products meet the highest technical demands, ensuring optimal performance in aerospace and other industries.

Contact us today with your filtration questions or project specifications, and discover how our metal mesh filter elements can improve efficiency, reduce maintenance, and boost system reliability. Experience the FCP difference and elevate your filtration systems to new performance levels.


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