Metal Mesh Air Filters | Aluminum Mesh & Custom Mesh Filters

Shop Metal Mesh Air Filters

Custom sizes (any height × width): 1-inch aluminum, 1/2-inch aluminum, 5/16-inch aluminum, 1-inch galvanized steel. Standard sizes in 1”, 2”, and 4” depths are listed below.

What Is a Metal Mesh Air Filter?

A metal mesh air filter consists of a rigid metal frame — aluminum or galvanized steel — containing multiple plies of corrugated criss-cross screen wire media. The corrugated structure creates a deep, three-dimensional filter bed through which air flows in a tortuous path. Particles too large to follow the airstream through the sharp changes in direction strike the metal wire surfaces and adhere through inertial impaction and interception. The more plies in the media pack, the more changes in direction the airstream must navigate and the higher the particle capture efficiency for a given airflow velocity.

AMFCO aluminum mesh filters use precision-formed aluminum alloy frames (.030” thick for 1” depth products, .025” thick for 1/2” depth) with 24-gauge aluminum face grids on both the upstream and downstream faces. The face grids provide structural support, prevent media displacement at rated airflow, and define the flat planar entry and exit surfaces of the filter. The media pack itself consists of 4 to 7 plies of corrugated criss-cross aluminum screen wire, depending on the depth and model — deeper filters have more plies and higher dust-holding capacity. All AMFCO aluminum mesh filters are UL 900 Class 1 listed and built to that specification for flame spread and smoke release.

The term “hand made mesh filters” is literally accurate: each custom-size order is individually cut, formed, and assembled by hand to the customer-specified dimensions. The aluminum frame is mitered, joined at corners, and secured with aluminum pop rivets; the corrugated screen wire layers are cut to size by hand and assembled into the frame. This manufacturing method is what makes exact custom sizing to 1/16-inch increments possible — a precision that automated production cannot replicate. Every filter exits the factory ready to install with no field modification required.

Technical Specifications — Aluminum Mesh and Galvanized Steel Mesh Filters

All specifications from AMFCO product data. Custom products (HIAS10, HIAS050, RHIS-0.313) and standard HI Series products share the same construction standards.

Available Products — Depth, Material, and Custom vs. Standard

Standard Size Reference — HI Series Aluminum Mesh Filters

Standard nominal sizes are stocked and ship quickly. All standard sizes follow the 1/2-inch undercut rule: actual H and W equal nominal minus 1/2 inch, ±1/16” tolerance. If your size is not listed, order custom: HIAS10 (1” aluminum), HIAS050 (1/2” aluminum), HIGS10 (1” galvanized).

1-Inch Nominal (7/8” actual depth)

2-Inch Nominal (1‑3/4” actual depth)

4-Inch Nominal (3‑3/4” actual depth)

Custom sizes in any height × width: 1-inch aluminum (HIAS10) — 1/2-inch aluminum (HIAS050) — 5/16-inch aluminum (RHIS-0.313) — 1-inch galvanized steel (HIGS10)

Applications for Metal Mesh Air Filters

Installation

Metal mesh air filters install in any panel filter housing that accepts the nominal or exact dimensions. Unlike pleated filters with a specific airflow direction, aluminum and galvanized steel mesh filters are non-directional — either face can be the upstream air-entry side. Standard HI Series filters follow nominal sizing conventions (actual = nominal minus 1/2 inch); custom HIAS and HIGS filters are built to exact specified dimensions, so install in slot sizes matching the ordered dimensions.

Before Installing

• Verify the nominal or exact size matches your filter housing opening
• For standard HI Series: actual dimensions are nominal minus 1/2” per face (±1/16”); confirm actual slot measurement against actual filter dimensions
• For custom HIAS/HIGS: filter is built to the exact H×W dimensions you ordered; confirm those match your measured slot dimensions
• Inspect the filter housing for existing debris and clean before installing
• Metal mesh filters can be installed in either orientation — no airflow arrow required

Installation Steps

1. Shut down the HVAC system before accessing the filter section
2. Remove any existing filter and clean the housing interior
3. Slide the metal mesh filter into the housing
4. Verify all four frame edges seat flush against the housing walls with no bypass gaps at the frame perimeter
5. Secure with the housing retention mechanism and close the access panel
6. Restart the system and note the installation date to track wash schedule

Cleaning and Maintenance

Aluminum and galvanized steel mesh filters are designed for repeated washing with warm water. There is no electrostatic media to recharge, no adhesive to reapply, and no special drying requirement. The mechanical filtration of the corrugated criss-cross screen wire is immediately restored at full function as soon as the filter is rinsed clean, with or without complete drying before reinstalling.

Washing Procedure

1. Remove the filter from the HVAC housing
2. Take to a utility sink, hose bib, or parts washer
3. Rinse with warm water from the clean (downstream) side through to the dirty (upstream) side
4. Continue until water flows through clear with no visible dirt
5. For heavily loaded filters, a brief warm soak before rinsing loosens compacted debris
6. Shake off excess water; air dry or reinstall damp — performance is immediate regardless of dry state (unlike electrostatically charged media)
7. Metal mesh filters can also be cleaned in a dishwasher (top rack, no heated dry) for commercial batch maintenance

How Often to Wash

• Light commercial HVAC pre-filtration: every 1–3 months
• Industrial or dusty environments: monthly or more frequently based on visual inspection
• Economizer service (outdoor air intake): seasonally, or after high-pollen events for spring/fall units
• Best indicator: visually inspect the upstream face; wash when the screen wire is coated with visible dust and debris that restricts airflow through the mesh

Frequently Asked Questions — Metal Mesh Air Filters

What is an aluminum mesh air filter?

An aluminum mesh air filter is a permanent, washable HVAC pre-filter constructed from corrugated criss-cross aluminum screen wire media held in a precision-formed aluminum frame. The corrugated mesh wire creates a tortuous path through which airborne particles collide and adhere to the metal surfaces. Aluminum mesh filters achieve approximately 43% dust arrestance efficiency, capturing large-particle dust, lint, hair, and debris that would otherwise coat HVAC coils and fans. They are designed for permanent installation — wash with water when dirty, reinstall, and repeat for years of service. Unlike disposable fiberglass or pleated paper filters, there is no replacement media to stock: the aluminum mesh filter is the product, not a consumable.

What does “hand made mesh filters” mean?

Custom-size aluminum mesh filters sold by American Metal Filter Company are quite literally hand-made to order. Each filter is individually cut, formed, and assembled by hand to the customer-specified height and width dimensions. The aluminum frame is precision-mitered, joined at corners, and secured with aluminum pop rivets; the corrugated criss-cross screen wire media layers are cut and assembled into the frame by hand. This hand-fabrication process is what enables exact custom sizing to 1/16-inch increments — dimensions that automated mass production cannot accommodate. The term “hand made mesh filters” accurately describes both the manufacturing method and the made-to-order custom nature of these products.

What is the dust arrestance efficiency of a metal mesh air filter?

Aluminum and galvanized steel mesh air filters achieve 43% dust arrestance efficiency per ASHRAE 52.1 synthetic dust testing. This places them in the MERV 1–4 range and identifies them as pre-filters or coarse-filtration filters rather than fine-particle filters. The design purpose of metal mesh filters is protecting HVAC equipment — coils, fans, motors, ductwork — from the larger particle fraction (lint, hair, insects, large dust agglomerates) that causes coil fouling and blower imbalance. They are not intended to capture fine dust, pollen, or allergens, and pairing a metal mesh pre-filter with a downstream fine filter (MERV 8–13) is standard practice in commercial HVAC systems.

What are the actual dimensions of HI Series standard aluminum mesh filters?

HI Series standard aluminum mesh filters follow the same 1/2-inch undercut convention used across AMFCO product lines: actual height and width equal nominal minus 1/2 inch, ±1/16 inch. A 20×25×2 nominal filter measures 19.5”×24.5”×1‑3/4” actual. A 24×24×4 nominal filter measures 23.5”×23.5”×3‑3/4” actual. Actual depths are 7/8” for 1-inch nominal, 1‑3/4” for 2-inch nominal, and 3‑3/4” for 4-inch nominal. Custom-size HIAS filters are built to exact specified dimensions (not nominal minus 1/2 inch) — specify the actual height and width you need for custom orders.

What depths are available for aluminum mesh filters?

AMFCO aluminum mesh filters are available in five depth options: 5/16” exact (RHIS-0.313, custom sizes only), 1/2” exact (HIAS050, custom sizes only), 1” nominal/7/8” actual (HIAS10 custom or HI Series standard), 2” nominal/1‑3/4” actual (HI Series standard), and 4” nominal/3‑3/4” actual (HI Series standard). The ultra-slim 5/16” and 1/2” depths are available in custom sizes only, sized to your exact specifications. Standard nominal sizes (16×20, 20×25, 24×24, and more) are available in 1”, 2”, and 4” depths as stocked products.

When should I choose galvanized steel mesh over aluminum mesh?

Choose galvanized steel mesh (HIGS10) when the application involves elevated temperatures or humidity levels that exceed aluminum’s optimal service range. Galvanized steel mesh filters are rated for 325°F continuous temperature versus 275°F for aluminum mesh. The hot-dip galvanized coating also provides enhanced corrosion resistance suitable for outdoor make-up air units with direct weather exposure, high-humidity industrial environments, kitchen exhaust pre-filtration, and equipment near marine or salt-air environments. For most standard residential and commercial HVAC applications operating below 275°F, aluminum mesh is equally suitable and the most common choice.

Can aluminum mesh filters handle high temperatures?

Yes. Aluminum mesh filters are rated for 275°F continuous temperature service, which covers the full operating range of residential and commercial HVAC systems including heat pumps, gas furnaces, and rooftop units. Galvanized steel mesh extends this to 325°F continuous. For extreme temperature applications above 325°F — industrial ovens, high-temperature process air handling, culinary exhaust — 304 stainless steel mesh construction is available (custom sizes) with temperature capability up to 900°F. The high-temperature rating is one of the primary advantages of metal mesh over pleated paper or electrostatically charged media, which are limited to much lower service temperatures.

How do I clean an aluminum mesh air filter?

Remove the filter from the housing and take it to a utility sink or hose bib. Rinse thoroughly with warm water directed from the clean (downstream) side through to the dirty (upstream) side. Continue until the water runs clear. For heavily loaded filters, a brief warm soak loosens compacted dust before rinsing. Allow to air dry completely before reinstalling. Metal mesh filters can also be cleaned in a parts washer or dishwasher (top rack, no heated dry) for commercial maintenance operations. Unlike electrostatically charged filters, no special drying procedure is required — the metal mesh construction provides the same mechanical filtration performance wet or dry, immediately upon reinstallation without any recharging period.

How do I order a custom size aluminum mesh filter?

Custom aluminum mesh filters (HIAS10 for 1” depth, HIAS050 for 1/2” depth) are ordered by specifying the exact actual dimensions — height × width — to 1/16-inch increments. For example, if your filter slot measures 15-1/4” × 24-3/16”, order exactly those dimensions. Custom filters are not returnable due to their made-to-measure nature, so measure your filter slot carefully before ordering. A standard conversion table (fractions to decimals) is provided on each custom product page. Turnaround is typically fast as each filter is hand-fabricated from stock aluminum frame and mesh wire in the USA.

Why Choose AMFCO Metal Mesh Air Filters

American Metal Filter Company has manufactured aluminum mesh and metal screen HVAC filters in the USA since 1973. Every mesh filter — custom or standard — is built to UL 900 Class 1 specification with the same precision-mitered aluminum or galvanized steel frame construction, the same corrugated criss-cross screen wire media, and the same dimensional tolerance (±1/16”) that commercial HVAC contractors and facilities managers rely on. Standard HI Series products in nominal stock sizes ship quickly for replacement needs. Custom HIAS and HIGS products are hand-fabricated to your exact specified dimensions, making them the correct solution for every discontinued filter slot, non-standard housing, and OEM replacement application where off-the-shelf products simply do not fit.

The economic case for a permanent metal mesh filter is straightforward. A custom aluminum mesh filter at a discontinued filter size eliminates a recurring search problem permanently: measure once, order once, wash and reinstall for 5–15 years of service. In commercial HVAC with a dozen or more filter positions, converting from disposable pre-filters to permanent aluminum mesh reduces ongoing procurement, labor, and disposal cost while maintaining consistent pre-filtration quality. The 43% dust arrestance of the mesh pre-filter keeps downstream coils and fine filters cleaner longer, reducing the frequency of expensive coil cleanings and extending the service life of downstream MERV 8–13 filters.

When the replacement requirement is an OEM aluminum mesh filter from a Carrier economizer, York rooftop unit, or Trane air handler, AMFCO stock compatible aluminum mesh replacements are available in exact OEM dimensions. See the Carrier, York, and Trane compatibility pages for OEM part number cross-references and exact replacement filter dimensions.

Related Filter Categories

Metal mesh filters span a range of media types, frame materials, and efficiency levels. Use the links below to navigate to the most relevant category for your application:

• Aluminum Screen Air Filters — HI Series — industrial aluminum, galvanized, and stainless screen wire; all HI Series sizes; material selection guide
• Washable Metal Air Filters — higher-efficiency washable options including EC Series MERV 6 and R8 Series MERV 8
• Economizer Filters — rooftop unit pre-filter cross-reference by brand and model