What are the main advantages of knitted metal mesh?

BVK's knitted-mesh material highlights high porosity, excellent conductivity, gas and liquid permeability, mechanical conformability, corrosion resistance, design flexibility and increased surface area.

Which knit types are available?

Supplied BVK literature references single, double and multi-end knitted mesh. A green-hydrogen leaflet also groups products by low-, medium- and high-density configurations for different stack functions.

Which materials can be used for knitted mesh?

BVK material references Nickel 201/202, copper, stainless steel, titanium, Hastelloy and specialty alloys. For hydrogen-focused applications, Nickel, titanium and stainless steel are specifically highlighted.

What wire-diameter range is referenced for knitted mesh?

The supplied knitted-mesh literature references wire diameters from 0.05 mm to 0.30 mm, with selection based on required strength, porosity, conductivity and stack performance.

Can knitted mesh be supplied in custom sizes or shapes?

Yes. BVK material describes continuous rolls, custom geometries and large single-piece capabilities. The exact maximum size depends on the selected product family and application, so the final capability should be confirmed against the project specification.

What finishing and forming options are available?

Knitted mesh can be degreased, annealed, coated or plated, and can also be crimped, corrugated, flattened or formed into application-specific profiles.

Where is knitted mesh used in hydrogen systems?

Supplied BVK material references alkaline electrolyser stacks, GDL or PTL-type layers, elastic elements, separators, electrode supports, H2 storage-related protection and other hydrogen value-chain applications.

Can knitted mesh properties be tuned for a specific cell or device?

Yes. Mesh density, wires per needle, needle gauge, stitch setup, wire chemistry, wire diameter and forming can be adjusted to tune pore size, conductivity, conformability, stack fit and flow behavior.

Flexible. High-performance. Application-driven.

Knitted MeshSolutions

Single, double and multi-end knitted wire mesh in nickel, titanium, stainless steel and specialty alloys — engineered for electrolyser stacks, GDLs and elastic elements.

High Porosity

Excellent Conductivity

Conformable

Corrosion Resistant

Discuss Knitted Mesh Download Leaflet

Illustration: pleated knitted mesh filter cartridge with end caps

High Porosity

Maximises reactant flow and water management.

Excellent Conductivity

Enhances electrical pathways for improved efficiency.

Mechanical Conformability

Fits irregular and layered component designs.

Large Single Pieces

Seamless components for large-scale assemblies.

Overview

Knitted for the
hydrogen value chain

BVK Hydrotech knits single, double and multi-end mesh on single-needle and double-needle machines built for green hydrogen work. The knitted loop structure gives you something a woven sheet cannot: porosity that stays open under compression, and a material that will deform into the shape of the component instead of fighting it. That is why it ends up in gas diffusion layers, separators and nickel elastic elements.

See the Knit Types

Illustration: mesh roll running through a manufacturing line

Single-piece

large-diameter capability

Three knit types

Engineered for the
hydrogen stack

Density is the primary lever. Each of the three knit types sits at a different point on it, and each maps to a different position in the stack.

Voltra Lite — Low Density

Single wire. Open gas diffusion layers and elastic elements where flow matters most.

Gas & Liquid Permeability

Supports optimal mass transport in electrochemical stacks.

Enhanced Surface Area

Ridges increase surface roughness, influencing adhesion, friction and interaction with coatings and fluids.

Voltra Max — High Density

Dense GDL and electrode support where contact area and conductivity dominate.

Voltra + — Medium Density

Double wire. Separator duty, balancing porosity, strength and conductivity.

Design Flexibility

Easily tailored to stack-specific or device-specific requirements.

Capability

What we can
knit and form

The knit is only half of it. Finishing and forming decide whether the part drops into your assembly or needs secondary work.

Knit type — single, double and multi-end
Wire diameter — 0.05 mm to 0.30 mm, adapted to strength and porosity needs
Materials — Nickel 201/202, copper, stainless steel, titanium, Hastelloy, specialty alloys
Mesh density — adjustable for porosity, permeability and mechanical resilience
Forms — continuous rolls, custom die-cut geometries, laser-cut precision parts
Finishing — crimped, corrugated (herringbone, W, V with variable angles) or flattened
Treatments — degreased, annealed, coated or plated

Illustration: knitted wire mesh showing the interlocking loop structure

Corrugation 4–10 mm

set against required elasticity

Specifications

Knitted mesh parameters

Parameter	Range	Sets
Knit type	Single, double, multi-end	GDL density and conductive path count
Wire diameter	0.05 mm – 0.30 mm	Pore size, surface area, stiffness
Wires per needle	Single / double / multi	Density and conductivity
Needle gauge	1 / 2 / 3+	With stitch length, pore size and cell fit
Single-piece diameter	Large single-piece sizes	Seamless large-diameter assemblies, sized per application
Corrugation	4 – 10 mm	Elasticity and contact pressure
Materials	Ni 201/202, titanium, stainless steel, copper, Hastelloy	Corrosion behaviour and conductivity
Standards	ASTM B164, ISO 9044, DSIR-RDI, ISO 22734-ready QMS	Qualification and audit evidence

Sustainability

Powering a cleaner planet

Woven and knitted mesh support electrolysers and fuel cells across the green hydrogen value chain. BVK also powers 50%+ of its energy needs through renewables, with a goal of becoming 100% self-reliant.

50%+

Energy needs powered by renewables

100%

Renewable self-reliance goal

Applications

Where knitted mesh
goes to work

Alkaline electrolysers, fuel cells and hydrogen balance-of-plant equipment are the core. Beyond them, anywhere a compressible, permeable metal layer is needed.

Alkaline Electrolysers

Nickel elastic elements, separators and stack core layers.

Fuel Cells & H₂ Storage

GDL, electrode supports and vent guards.

Illustration: Hydrogen plant filter module

BoP Filter Elements

Balance-of-plant filtration and support structures.

Illustration: Hydrogen purification and storage

Purification & Drying

Mesh internals for H₂ purification and drying skids.

The BVK competitive edge

More than mesh —
confidence

With the ability to produce custom sizes in a single piece, BVK enables seamless integration into advanced systems. Integrated R&D and prototyping, supported by CFD modelling, ensures optimal structure and performance from concept to scale-up.

Seamless Integration

Single-piece capability removes joints from large circular components.

CFD-Backed Development

Flow modelling before scale-up, from a DSIR-recognised R&D centre.

Certified Sourcing

Global certified material sourcing with a documented supply chain.

ESG-Compliant Manufacturing

Electrolyser Solutions

Fuel Cell Solutions

Woven Mesh Solutions

Let's build a cleaner tomorrow

Engineering mesh for the future

Tell us the cell chemistry, the envelope and the density you are targeting. BVK combines design, material science and process know-how to turn that into a knitted component.

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Certifications

Certified quality, safety and compliance

The same management systems and compliance badges audited across every order: quality, environment, safety, energy and material conformity.

AS9100

CE Marking

DSIR Recognized R&D Centre

IATF 16949:2016

ISO 9001:2015

ISO 14001:2015

ISO 45001:2018

ISO 50001:2018

REACH Compliant

RoHS Compliant