Manufacturing with expertise

It is important to us that our customers receive products and product solutions from us that are durable. They should also be individual and versatile so that they meet our customers’ requirements.

Home > Competence > Manufacturing

Technical solutions from the global market leader

GKD stands for precise mesh made from metal and plastic wires as well as technical fibers – ready for industrial use in all sectors. We use these materials to manufacture efficient mesh, process belts, components, filter systems and architectural mesh.

We select the right and appropriate manufacturing process for the respective application. Our customers can rely on us to meet their individual requirements.

Sophisticated and durable
High-quality fabric is made from the right material and with the right weave

We work with durable materials such as metal or polymers and with sophisticated substances such as basalt, glass, or ceramics. In accordance with the individual wishes of our customers, we produce high-quality and durable industrial meshes, filters, filter elements, or mesh laminates – either in series production or as one-offs. Compound products are just as possible as high-precision mesh made of a single material.

When selecting the right type of weave, our customers can rely on our 100 years of experience. The production of mixed constructions, multi-dimensional weave structures, multi-layer constructions, weaves made of special alloys, and production under clean room conditions for special requirements are standard for us.

Individual and versatile
With our specially developed machines, we make customer wishes possible

In order to be able to create individual solutions for our customers in niche markets, we at GKD design and manufacture our own machines together with our partners. In contrast to standard machines, these allow us to produce versatile and high-quality meshes that are precisely tailored to the needs of our customers.

Thanks to our special machinery, we can produce just-in-time and process all common materials as well as ultra-fine wires from 16 μM. Ultra-fine meshes up to a width of two meters and a weaving width of up to six meters for other meshes are also possible.

Optimal and precise
After weaving, 90% of all GKD industrial meshes undergo finishing operations or subsequent processing

After production, the industrial fabrics are cleaned. We use thermal processes and coatings to permanently ensure the desired material properties and the mesh bond. Finally, we cut and join each product individually. The result of all this is a reliable, durable, and economical product for industry. We process these further into individual solutions or hand them over to our customers as semi-finished products.

A selection of our processing and finishing methods:

Coating
Joining
Degreasing
Annealing with the shielding gas process
Calendering
Marking seams
Bonding
Laser cutting

Solution annealing
Soldering
Plasma cutting
Mechanical cutting/stamping
Cleaning
Sintering
Welding
Wrapping

Weaving

Weaving is GKD’s core competence. With decades of experience and state-of-the-art technology, we produce high-quality metal and plastic mesh for industrial applications as well as architectural mesh. Our meshes impress with their precision, durability and versatile customization options.

Whether for filtration, drying or as a building façade – we develop fabrics that are optimally tailored to the requirements of our customers. Our expertise in various weaving technologies enables us to provide customized solutions for a wide range of markets.

Cleaning

Various cleaning systems are available at GKD for cleaning and degreasing. Ultrasonic-assisted cleaning baths for coil/roll goods and for finished products are used to remove process-related oils and abrasion from the fabric surface. This type of cleaning is gentle on the material and effective.

For particularly high cleaning requirements, fabrics are subjected to a thermal cleaning process. Organic contaminants and oxides are removed in a 100% hydrogen atmosphere above 1000°C (reduction annealing).

Fabrication

In order to be able to offer our customers ready-made products, GKD has all common cutting technologies in-house. Depending on the tolerance requirements and fabric types, cutting processes such as laser cutting, plasma cutting, knife cutting or blade cutting are used on CNC-controlled cutting systems. In particular, ripple-free, secured cut edges can be realized using our cutting technologies (e.g. plasma cutting), edge post-treatment (e.g. edge desoldering) or heat treatment (DKS diffusion annealing calender cutting).

Joining technology

Joining wire mesh is no great challenge for GKD. We select the optimum process depending on the mesh type, mesh width and wire thickness combination. GKD has decades of experience in all common welding, soldering and bonding processes in-house. GKD uses fusion welding, resistance welding and soldering and bonding, which are more gentle on the material.

Fusion welding: laser welding, TIG welding, microplasma welding
Resistance welding: spot welding and roll seam welding (50Hz and medium frequency technology), KE welding (capacitor discharge welding)
Soldering: hard soldering, soft soldering
Bonding: 2-component adhesives, 1-component adhesives

Seam technology

Customized seam solutions for optimum process integration. Just like our belt solutions, their seams also have to withstand tough conditions. Depending on the application, we combine the optimum mesh for the specific customers with a suitable seam type. We are also happy to advise you on which seam to choose for your individual application.

The patented and particularly flat PAD seam is exclusively available from GKD. A special pad is melted into the belt mesh and pressed together with metal hooks in a hot melt process. This not only offers greater strength, but also leads to better belt running characteristics. In addition, the risk of damage to the seams is reduced significantly, the seam area is closed more tightly, and product penetration is reduced.

Heat treatment

The heat treatment of fabrics is a further finishing stage that is carried out at GKD. It serves various purposes, such as improving the mechanical properties, increasing corrosion resistance and adapting the microstructure of the material. Various thermal treatments are carried out in a hydrogen atmosphere in a continuous furnace specially developed for metal mesh. We operate and test our heat treatment plants in accordance with CQI9, not only because of GKD’s IATF 16949 certification. We also serve our customers in the oil production industry on the basis of API6A.

A selection of our processing and finishing methods:

Recrystallization annealing / stress relief annealing: to restore the physical properties after the weaving process (work hardening). Reduces internal stresses, increases ductility, improves strength and reduces the risk of cracking.
Diffusion annealing: to join the warp and weft wires. This prevents mesh displacement and wires falling out when cutting/punching the treated fabrics. It also forms the basis for the DKS fabric (DKS diffusion annealing-calendering-cutting).

Reduction annealing: serves to remove oxides and other impurities from the fabric surface.
Heat setting: refers to the thermal process used to improve the properties of our technical fabrics. For example, the customer-specific settings of the heat setting process increase the dimensional stability and prevent unwanted shrinkage or elongation in subsequent customer applications. The tendency to wrinkle is also reduced.

Strip cutting

Strip cutting of fabrics is an important after-weave service at GKD. Our customer uses the fabric strip for its fully automated production lines. Long lengths and uniform winding of the fabric rolls are essential for automated processes. Strip widths of less than 5mm and lengths of over 1000m are possible. Fixed knife blocks (slitting system), rotating or driven knives or blades for cutting within the fabric mesh are used for high-precision strip production. Here too, the edges can be secured against rippling using the plasma cutting process or DKS treatment. Just as important as the exact cut edge and strip width is the constant winding tension and precise edge winding. These requirements are met by regulated friction shafts and web edge controls, which ensure the quality of the rolls on the slitting and winding systems.

For particularly sensitive applications, an optical inspection system uses highly sensitive cameras to monitor the fabric surface and select deviations that can be ejected later in the process.

Rolling / Calendering

GKD precision calenders can be used to precisely adjust the physical properties of woven wire cloth. During calendering, the wire crests are flattened. This ensures a smooth mesh surface. Furthermore, the mesh weave is stabilized and a defined mesh thickness can be achieved, which is required for subsequent production processes. Depending on the mesh weave, even the filter fineness can be influenced by this process.

GKD uses precision calenders in various widths. Metal mesh can be precisely calendered to a defined thickness with a tolerance of +/- 0.002 mm.

Punching / Forming

Punching, forming and deep drawing are becoming increasingly important processes at GKD. GKD uses several fully automated production lines for series products and large quantities. High-performance cameras monitor the quality online. Here, 3-dimensional filter elements (single or multi-layer) with or without edgings are produced for various applications. However, GKD also offers a wide range of different punched products for small and medium quantities on automatic punching, bending and forming machines. GKD has a wide range of machines and tools available for contour punching, deep drawing, edging or edge pressing of metal mesh. GKD also offers solutions for plastic injection molding of fabric parts.

Coating

Maximum wear protection with PVD coating: Extend the service life of your products – Our Physical Vapor Deposition (PVD) technology offers you a decisive competitive advantage: outstanding wear protection for your products. Whether in the textile, automotive or aviation industry – with our PVD coating you can significantly increase the service life and reliability of your products. Our system ensures an extremely resistant surface that protects your materials from abrasion and wear.

PVD coatings: The key to maximum wear protection

Our PVD coating gives your products an extremely hard and durable surface that effectively protects against mechanical stress and significantly extends their service life.

Your benefit: Maximum abrasion protection. Our PVD coating minimizes wear and significantly increases the service life of your products.

Where PVD coatings make the difference

Our PVD coatings are used wherever products have to withstand extreme mechanical stress. Here are some examples of applications:

Cutting tools: Increase the service life and cutting performance of your tools in metal and wood processing.
Filtration mesh: Extend the service life of your metal filter mesh many times over without changing the basic mesh properties. Our PVD coating offers decisive advantages, particularly in areas of application where wear-related failure causes high costs.
Mold making: Protect your injection molds and tools from abrasion to ensure consistent production quality.
Automotive components: Ensure the durability and efficiency of engine components, transmission parts and brake systems.

Textile machinery: Increase the durability of components exposed to high friction and mechanical stress.
Aerospace: Protect turbine blades and other high-performance components that are exposed to extreme temperatures and mechanical stresses.
Medical technology: Rely on PVD coatings for surgical instruments and implants that require high wear resistance and biocompatibility.
Electronic components: Avoid wear and ensure long-term functionality of contacts and connectors.

Large-format PVD coatings: Protection without compromise

Our PVD coating system offers you the option of coating even particularly large components efficiently and seamlessly. This is particularly interesting for industries that rely on large-area, wear-resistant materials.

Advantages of our large-format PVD coating:

Seamless protection: even large-format components can be coated without interruption, ensuring a uniform and continuous protective layer.
Scalability: Our technology allows you to scale production without compromising the quality of wear protection.

Conclusion: Extend the service life of your products with PVD coating

With our PVD coating technology, you can rely on maximum wear protection and extend the service life of your products. Our PVD coating reduces maintenance requirements and minimizes the risk of system failures – and therefore high follow-up costs – particularly in applications subject to heavy wear, such as metal filter meshes. Rely on our expertise to protect your products from wear and tear and take their performance to a new level.