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POROSTAR®

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PORPOROSTAR® wire mesh laminates are high-performance, multi-layered filter media engineered for precision filtration in demanding environments. Designed for durability, consistency, and customizability, POROSTAR is ideal for applications that require fine particle retention, structural integrity, and long service life.

What Is POROSTAR?

POROSTAR wire mesh laminate can have variating layer configurations and has proven to excel in solid-liquid filtration and hot gas filtration applications.

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Challenges Sintered Wire Mesh Laminates Can Solve

Inconsistent Flow Distribution

Uneven flow through the column can lead to inaccurate separations and longer run times. Sintered mesh laminates offer uniform pore structure, promoting even flow across the entire column.

Particle Migration and Media Loss

Without a stable frit, packing media can migrate or leak, degrading performance. The precise retention capabilities of sintered mesh prevent particle loss while supporting the stationary phase.

Pressure Instability Under High Loads

HPLC systems operate under extremely high pressures. Sintered laminates provide exceptional mechanical strength and dimensional stability to prevent deformation or failure under stress.

Channeling

Improper frit design can create paths of least resistance, causing channeling. Laminated mesh helps eliminate dead zones by evenly distributing pressure and mobile phase flow.

Limited Chemical Compatibility

Harsh solvents and pH extremes can corrode or degrade some frit materials. Stainless steel sindered mesh offers broad chemical resistance to extend component lifespan.

Frequent Frit Replacement or Downtime

Traditional frits may clog or deform over time requiring frequent maintenance. Sintered wire mesh frits resist clogging and wear, reducing downtime and increasing system uptime.

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Precision Performance for Every Layer of Your Process

  • Porostar® Standard

    POROSTAR spec is used in filter sheets and cylinders. It is designed with five or six layers and is especially suitable for unbalanced loads.

  • Porostar® Light

    POROSTAR spec suitable for the manufacturing of pleated filter cylinders and discs with very small diameters, e.g., 2.5 mm, and is composed of three woven wire cloth layers.

  • Porostar® Hiflo

    Because of its important flow capacity, POROSTAR® HIFLO is especially suitable for sieving and filtering methods using minimized pressures. Each woven wire cloth layer has square meshes.

  • Porostar® Combi

    POROTAR spec is suitable for high pressures even in reverse-direction flow. Woven wire cloth layers and a perforated metal plate are bonded by sintering. POROSTAR® Combi is available in standard type and in special types of light or HIFLO as well. The number of layers and the thickness of the perforated metal plate are variable.

Wire Mesh, Reinvented

Engineered for precision. Built To Last

Duo Sintering Technology

The duo-sintering technology results in the diffusion of all wires in contact with each other without changing the geometric structure of the individual cloth layers. The result is a stable, porous filter medium with characteristics that can be determined in advance.

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Hand-Picked Specialty Alloys

POROSTAR is offered in various stainless steel and specialty alloys, delivering chemical resistance, thermal stability, and strength tailored to your process. The result is reliable performance, less downtime, and greater efficiency

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Peak Weldibilty

POROSTAR® panels can be expertly welded to create larger formats without compromising strength or precision. This includes custom assemblies like filter plates over 1,200 mm and filter cylinders over 400 mm in diameter.

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Industries We Serve

Discover how woven wire rolls and cut-to-size pieces enable you to craft best-in-class solutions in-house while maintaining a reliable wire mesh inventory.

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  • Aerospace
  • Automotive
  • Chromotography
  • Pulp and Fiber
  • Water Filtration
  • Plastics and Extrusion
  • Oil and Gas
  • Carbon capture

Repair Without Compromise

Even the toughest filter elements wear down over time. POROSTAR® is built to last, but it’s not invincible. The good news is you don’t always have to start from scratch. Whether you need a full replacement using your existing flange ring or a simple repair, you have options to keep things running smoothly and extend the life of your equipment without unnecessary downtime or cost.

Partial Repair

Sometimes only a small section of your POROSTAR® laminate is affected. Instead of replacing the entire part, we can remove the damaged area and integrate new mesh directly into the original structure. This partial repair restores performance, reduces downtime, and saves costs by preserving as much of the original component as possible. It is a practical way to keep your operation moving without a full replacement.

Localized Damage

Partially damaged wire mesh laminate with localized wear, making it a strong candidate for targeted repair. This approach allows you to restore full functionality without replacing the entire component, helping to reduce material waste, shorten repair time, and lower overall maintenance costs.

Lasting Solution

Repaired wire mesh laminate featuring a precisely integrated replacement section. This seamless restoration returns the component to peak performance, reduces the need for full replacement, and helps extend the overall service life while keeping costs and downtime to a minimum.

Cost Efficiency

Fixing just the damaged section of your POROSTAR® mesh laminate helps lower both repair costs and downtime compared to replacing the entire unit.

Reduced Downtime

Partial repairs on your POROSTAR® wire
mesh laminate help minimize downtime,
keeping your operation running smoothly
without waiting on a full replacement.

High Quality

The repaired wire mesh laminate is built
to meet the same high standards as the
original, delivering long-lasting performance
you can count on.

Effective Restoration

Tailored repairs make it easy to fix only
 what’s needed, restoring filter performance
quickly and efficiently without unnecessary
waste, added effort, or extended downtime.

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Complete Repair

In cases where your POROSTAR® laminate is fully worn or damaged, a complete repair may be the best solution. We replace the entire mesh laminate while preserving key components like the flange ring whenever possible. This approach restores full performance, extends the life of your equipment, and helps you avoid the cost of replacing the entire assembly. It is an efficient way to get back to peak operation with minimal disruption.

Critical Damage

Completely worn wire mesh laminate disc beyond the point of targeted repair. When damage is this extensive, a full replacement is the most effective solution to restore filtration performance, ensure long-term reliability, and keep your process running efficiently with minimal disruption.

Total Overhaul

Fully repaired wire mesh laminate filter plate with brand-new filter media installed and original components, such as the flange ring, preserved where possible. This complete restoration ensures renewed performance, improved reliability, and minimized material waste.

Cost Efficiency

By reusing the existing flange ring, you cut down on material waste and lower overall wire mesh repair costs, making the process more efficient and budget friendly.

Time Savings

Reusing the existing flange ring speeds up 
the repair process, helping you get back to 
full operation faster with less downtime.

High Quality

Each replacement wire mesh laminate is
 built to strict quality standards, ensuring 
reliable performance, lasting durability, and 
effective filtration.

Sustainability

Reusing the flange ring reduces material 
waste, making the repair process a more 
sustainable, effective, and environmentally 
friendly solution.

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Frequently Asked Questions

POROSTAR® wire mesh laminate is a carefully engineered, multi‑layer metallic porous material created by bonding multiple woven wire mesh layers into a single, stable structure. Each layer contributes to the overall performance, allowing porosity, thickness, and strength to be precisely controlled.

Unlike loose or single‑layer meshes, the laminated construction prevents layer movement, deformation, or collapse during operation.

The result? A material that delivers predictable flow behavior, structural reliability, and long‑term performance in demanding environments.

POROSTAR® addresses several limitations common to conventional filtration and flow media. Single‑layer meshes may deform or shift, fiber media can degrade or shed, and polymer structures often fail at elevated temperatures or pressures. POROSTAR® solves these issues by providing:

· Structural stability under load
· Defined and consistent porosity
· Resistance to vibration, pressure cycling, and thermal stress
· Long‑term performance without material breakdown

This makes POROSTAR® especially valuable in applications where failure is costly, unsafe, or difficult to service.

POROSTAR® is highly customizable and designed to be engineered around the application, not the other way around. Customization options include:

· Mesh count combinations and layer orientation
· Wire diameters and weave styles
· Target porosity, permeability, and thickness
· Mechanical strength and rigidity requirements

This flexibility allows engineers to balance competing design requirements such as flow rate, filtration efficiency, pressure drop, and structural strength.

POROSTAR® wire mesh laminates are available in a range of metallic materials selected to meet environmental and performance demands. Common materials include stainless steels for corrosion resistance and strength, as well as nickel‑based or specialty alloys for extreme temperature or chemically aggressive environments.

· Stainless Steel 316L
· Stainless Steel 316Ti
· Stainless Steel 904L
· Hastelloy C22
· Alloy 59
· Inconel 600
· Carpenter 20 Cb 3
· AVESTA 254 SMO

Material selection ensures compatibility with operating fluids, temperatures, pressures, and regulatory requirements.

Selecting the right POROSTAR® wire mesh laminate configuration starts with a clear definition of the application’s operating conditions and performance goals. Engineers typically evaluate required flow rate, allowable pressure drop, operating temperature and pressure, expected contaminant type and size, and any mechanical or space constraints within the assembly. These inputs establish the baseline performance requirements and help identify potential trade‑offs, such as balancing higher permeability for flow efficiency against finer pore structures for filtration effectiveness.

From there, the POROSTAR® laminate is engineered by adjusting mesh layer combinations, wire diameters, thickness, and material selection to achieve the optimal balance of permeability, strength, and durability. Material choice ensures compatibility with temperature, chemical exposure, and long‑term service conditions, while laminate structure is tailored to resist deformation, vibration, and pressure cycling. In many cases, engineers collaborate with technical specialists to model performance, compare pressure drop behavior, and validate designs through testing, reducing risk and ensuring the final configuration delivers reliable, repeatable performance throughout its service life. To ensure you are best equipped for the initial conversations, you should have the following information available:

· Any associated shop drawings
· Required material
· Desired layer Configuration
· Filter layer specifications
· Throughput requirements
· Operational environment (Temperature ranges, chemical exposure, Operating pressure ,etc. )
· Any specs/compliance/standards needed to be meet

Essential Product Information For You

  • Porostar® Nutsche Plate Repair: Everything You Need to Know

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  • How Porous Wire Cloth Laminate Filters Benefits Nutsche Filter Dryers

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  • What Are Sintered Porous Stainless Steel Filters (Porostar®)

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