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Calculate opening from known mesh count, or estimate mesh count from a required aperture.
Engineering Tool · Woven Wire Mesh
Wire Mesh Size Calculator: Mesh, Micron & Open Area
Calculate square woven wire mesh aperture, micron size, pitch and theoretical open area from mesh count and wire diameter—or estimate mesh count from a target opening.
Important: mesh count alone does not determine micron opening. Wire diameter is required for an accurate woven-mesh estimate.
Enter mesh specifications
Values recalculate automatically; use the button to confirm.
Number of openings per linear inch or centimetre.
Clear opening between adjacent wires.
Finished wire diameter after weaving/coating.
Calculated results
Theoretical values for square openings.
Aperture0.154 mm0.006063 in
Micron opening154 µm1 mm = 1,000 µm
Pitch0.254 mmcentre-to-centre distance
Open area36.76%theoretical surface ratio
Estimated mesh count100 mesh/in39.37 mesh/cm
Formula used
Aperture (mm) = 25.4 ÷ mesh count − wire diameter (mm)How to use the calculator
Enter wire diameter
Use the finished diameter. Coatings and weaving deformation can change the actual value.
Verify for production
Use the result to shortlist specifications, then confirm with samples, drawings or inspection data.
For practical sample checks, see the guide to measuring count, wire diameter and aperture. Record actual readings separately from calculator estimates. For the meaning of mesh count and clear opening, read mesh count versus micron. To turn a geometric result into ordering information, use the wire mesh specification guide.
Formula and applicability
For square woven mesh, pitch equals one inch divided by mesh count. Clear aperture is pitch minus wire diameter. Theoretical open area is the square of aperture divided by pitch.
Aperture: a = 25.4 ÷ n − d
Pitch: p = 25.4 ÷ n
Open area: OA = (a ÷ p)² × 100%
This calculator is intended for plain or twill woven wire cloth with nominally square openings. It is not suitable for Dutch weave, reverse Dutch weave, knitted mesh, expanded metal, perforated sheet, sintered laminate or irregular/crimped openings.
Actual aperture can vary with wire tolerance, weave tension, coating thickness, edge condition and measurement method.
Worked examples
| Mesh count | Wire diameter | Aperture | Micron | Open area |
|---|---|---|---|---|
| 20 mesh/in | 0.40 mm | 0.870 mm | 870 µm | 46.93% |
| 60 mesh/in | 0.18 mm | 0.243 mm | 243 µm | 33.04% |
| 100 mesh/in | 0.10 mm | 0.154 mm | 154 µm | 36.76% |
| 200 mesh/in | 0.05 mm | 0.077 mm | 77 µm | 36.76% |
Frequently asked questions
Is mesh count the same as micron rating?
No. Mesh count describes openings per linear unit; micron describes opening size. The wire diameter must also be known to calculate the clear aperture.
Why can two 100-mesh screens have different openings?
They may use different wire diameters. A thicker wire leaves a smaller clear opening at the same mesh count.
Does open area predict flow rate or filtration efficiency?
No. Open area is one geometric input only. Flow and filtration also depend on fluid properties, pressure, weave, layer count, contamination loading and downstream support.
Can I use this result as a manufacturing tolerance?
No. Use it for preliminary selection. Final tolerances should be defined on an approved drawing or applicable inspection standard.
Need a production-ready mesh specification?
Share the target opening, material, operating conditions and required format with our engineers.
Engineering disclaimer: Use the theoretical result to shortlist a square-opening mesh specification. Record mesh count, wire diameter and target aperture together, then agree tolerances on the drawing and verify the sample. Confirm application performance through the required testing and engineering review.
Compare Two Square Woven Mesh Specifications
Compare theoretical opening, open area and weight per square metre for two square-opening woven mesh specifications. Use the same unit basis for both. The weight is a round-wire geometric estimate and requires an entered density and crimp allowance.
Press Compare specifications to calculate.
Engineering limits
Opening = 25.4 ÷ mesh count − wire diameter (both dimensions in mm). Theoretical open area = (opening ÷ pitch)² × 100%. Estimated mass per area = 2 × (mesh count ÷ 0.0254) × π(d/1000)²/4 × density × (1 + crimp/100) kg/m². The weight estimate assumes equal warp and weft count and round-wire diameters; it is not a measured finished-roll weight.
Different wire sizes can change opening, open area and mass even when mesh counts are equal. The model does not apply to Dutch weave, reverse Dutch weave, knitted mesh, sintered laminates, distorted openings or mixed warp/weft specifications. Verify feasible weave, tolerances, weight and filtration performance using drawing and samples. For a roll or cut part, continue to the existing weight calculator and enter real width, length and quantity.