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Custom Foam Filter
This page lists all 3 Custom Foam Filter replacement filters available from Metal Air Filters — precision-manufactured washable aluminum mesh filters engineered as direct OEM replacements for Carrier commercial HVAC equipment. All filters on this page are HI Series products manufactured by American Metal Filter Company (AMFCO) with .030" extruded aluminum alloy frames, corrugated aluminum mesh media, UL 900 Class 1 certification, and a 275°F maximum operating temperature rating.
Each filter is a permanent washable replacement — clean and reuse for 5–10 years rather than replacing disposable filters every 30–90 days. AMFCO’s aluminum mesh construction provides 43% average dust arrestance per ASHRAE 52.1, making these filters ideal pre-filters in multi-stage Carrier commercial HVAC systems protecting downstream MERV 8 through HEPA filtration stages in rooftop units, air handlers, and split systems.
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Key Benefits of Custom Foam Filter Washable Aluminum Mesh Filters
- Made to Your Dimensions: Fabricated to the exact height and width you specify—ideal for non-standard housing sizes, retrofit HVAC applications, and electronic equipment enclosures where off-the-shelf catalog sizes do not fit. Provide your required dimensions when ordering and receive a precision-built filter with ±1/8” dimensional tolerance
- MERV 4 Rated — Two-Stage MERV 4 dust filtration foam filter: Same two-stage progressive density media as catalog HFA products: stage 1 aluminum mesh foam prefilter prefilter captures large particles, stage 2 25 ppi open-cell polyurethane foam captures fine particles, together delivering MERV 4 efficiency at low air resistance suitable for electronics, HVAC, and machinery ventilation foam air filter
- Low Air Resistance — Suitable for Electronics: The HF Series MERV 4 foam air filter maintains low static pressure drop at rated 300 fpm, making the HFAS10 appropriate for electronics cooling, computer rooms, and other airflow-sensitive applications where excessive filter resistance would reduce cooling effectiveness
- Permanent washable MERV 4 foam filter design: Rinse with warm water to restore full MERV 4 filtration performance—no replacement media required. Eliminates recurring disposable filter cost for non-standard sizes that may be difficult to source as disposables
- 250°F Maximum Operating Temperature: Rated for continuous operation at temperatures up to 250°F, suitable for commercial air handlers, light industrial ventilation, and HVAC applications with elevated supply air temperatures
- All-Aluminum Frame Construction: .030” thick aluminum frame with precision-mitered corners and pop-rivet construction fabricated to your specified height and width, with drain holes in three corners for frame drainage
- Flexible Installation — Vertical or Horizontal: No orientation restriction—install the HFAS10 vertically or horizontally to suit your housing configuration
- Made in USA by AMFCO — UL Classified 900: Manufactured by American Metal Filter Company to the same construction standards as catalog HFA products
Available Custom Foam Filter Filters — Complete Product Listing
All 3 Carrier-compatible washable aluminum mesh replacement filters available from Metal Air Filters, with nominal size, actual dimensions, and current pricing. Click any part number for full product details, specifications, and purchasing.
| Compatible Part No. | Nominal Size | Actual Dimensions | AMFCO SKU | Price |
|---|---|---|---|---|
| Custom Foam Air Filter, 1 Inch Thick | 7/8″ (±1/16”) — height and width fabricated to customer spec (±1/8”) | HFAS10 | $— | |
| Custom Foam Air Filter, 1/2 Inch (0.50″) | 1/2″ (±1/16”) — height and width fabricated to customer spec (±1/8”) | HFAS050 | $— | |
| Custom Foam Air Filter, 2 Inch Thick | 1-3/4″ (±1/16”) — height and width fabricated to customer spec (±1/8”) | HFAS20 | $— |
Common Specifications — HI Series Aluminum Mesh Filters
The following specifications apply to the HI Series aluminum mesh filters on this page. Individual products vary by nominal size, actual dimensions, dust holding capacity, and OEM compatibility — see each product page for complete product-specific specifications.
| Specifications: | Details: |
|---|---|
| Frame Material | .030” thick aluminum |
| Frame Construction | Precision-mitered corners secured with pop rivets; drain holes in three corners |
| Filter Type | Two-stage impingement type washable foam and aluminum panel filter — custom make-to-order |
| MERV Rating | MERV 4 |
| Dust Holding Capacity | 24 grams per square foot |
| Rated Airflow | 300 fpm face velocity |
| Recommended Airflow Range | 250–350 fpm |
| Maximum Operating Temperature | 250°F continuous |
| Recommended Final Resistance | 0.50 inches W.G. before cleaning |
| Washability | Frequent and moderate |
| Compliance & Certifications | UL Classified 900 |
| Country of Origin | Made in USA |
Commercial & Industrial Applications
Carrier commercial HVAC equipment is deployed across a wide range of commercial, institutional, and industrial building types. The following applications represent the primary use cases for Custom Foam Filter permanent washable aluminum mesh filters.
The HFAS10 custom 1-Inch MERV 4 foam air filter is specified for commercial, residential, electronics, and light industrial HVAC applications where standard catalog HFA filter sizes do not match the required housing dimensions. The make-to-order capability allows engineers and facilities managers to specify precise filter dimensions for retrofit projects, non-standard ductwork, existing housings with unusual dimensions, and electronic equipment enclosures requiring exact sizing.
Non-Standard Housing Retrofit Applications
Buildings with HVAC systems installed with non-standard filter housing dimensions that do not match current catalog sizes frequently require custom-dimensioned filters. The HFAS10 provides the same HF Series two-stage MERV 4 filtration in a filter built to the exact dimensions required for proper fitment in these non-standard housings, eliminating bypass gaps that reduce filtration efficiency.
Electronics and Equipment Cooling
Electronic equipment enclosures, server room air conditioning units, and precision cooling systems frequently have non-standard filter section dimensions. The HFAS10 custom filter provides MERV 4 efficiency at low static resistance in a 1-Inch MERV 4 foam air filter built to the exact dimensions of your equipment, with no UV exposure at the filter location.
Machinery Ventilation
Industrial machinery ventilation systems with ductwork fabricated to plant-specific dimensions require custom filter sizing. The HFAS10’s aluminum mesh and foam construction captures industrial dust and particulate in custom-dimensioned filters that fit precisely in machinery ventilation housings without air bypass.
Custom Foam Filter — Related Search Terms
Customers searching for foam air filters, foam filters, and air filter foam block will find all compatible washable aluminum mesh replacement filters on this page. All custom foam filter products shown here are manufactured by American Metal Filter Company (AMFCO) as permanent, washable OEM replacements for Carrier commercial HVAC equipment. Whether searching for foam air filters by Carrier part number or by nominal size, each filter shown here ships directly from AMFCO with full compatibility documentation.
Frequently Asked Questions
What dimensions can I specify for the HFAS10?
Height and width can be specified in 1/8″ increments to your exact requirements. The nominal depth is fixed at 1″ (7/8″ actual depth per HF Series convention). Contact Metal Air Filters with your required height and width to receive a quote and confirm lead time.
How does the HFAS10 two-stage foam filter work?
Stage 1 aluminum mesh (expanded aluminum grid + corrugated screen wire criss-cross) captures large airborne particles. Stage 2 25 ppi foam captures finer particles. MERV 4 rated, 75% at rated airflow (300 fpm), 24 grams per square foot. Progressive density extends wash intervals.
Can I apply adhesive to the HFAS10?
No. AMFCO explicitly states adhesive coating is not advisable for HF Series foam filters. The two-stage construction provides mechanical capture without adhesive.
Can the HFAS10 be exposed to sunlight?
No. DO NOT place in direct sunlight or UV light. UV radiation degrades the polyurethane foam media over time. Store and install away from UV sources.
What is the lead time for a custom HFAS10 order?
Lead time varies by dimensions and production schedule. Contact Metal Air Filters with your required dimensions and quantity to receive a current lead time quote. Custom orders cannot be returned or exchanged once production begins.
What is the maximum operating temperature?
250°F continuous operation. Covers commercial and residential HVAC. For dust filtration at higher temperatures consult Metal Air Filters.
Can the HFAS10 be installed vertically or horizontally?
Yes — no orientation restriction. The HFAS10 delivers full MERV 4 filtration in either vertical or horizontal mounting.
How often should I wash the HFAS10?
General HVAC: every 1–3 months. Electronics/computer room: every 3–6 months. Machinery ventilation: monthly or as needed. Inspect visually and wash when the aluminum mesh face appears loaded.