Micro metal mesh structures are used in many applications including light, air, sound, and matter filtration. They are also used in applications such as electron and proton accelerators for advanced physics experiments and detectors. Typically, these micro metal mesh structures are created by electro-depositing metal into a lithographically defined photo-resist mold, creating an all-metal mesh. However, for some applications an all-metal mesh is not desirable, for example if emission of secondary electrons or photons by the metal mesh needs to be avoided.
To address our customer's need for an electrically conductive mesh that doesn't emit secondary electrons or photons, we constructed a metal mesh comprised of a 6 micron thick polymer with a 50 nm thick layer of gold. Using our proprietary rapid direct-write nano-ablation process we ablated through the structure allowing rapid production of the mesh structure that maintains electrical conductivity while minimizing the amount of metal in the structure. A wide variety of mesh structures are possible with this method. Custom designs can be rapidly manufactured according to the specs provided.