Mesh Welding

Weld Metal Mesh, Foil, and Sheets.

Weld metal mesh, foils, and sheets with resistance seam welding (RSEW) technology.  Resistance seam welding (RSEW) is a type of resistance welding where a circular electrode is “rolled” over overlapping surfaces. This wheel is Manufactured using RWMA Welding Copper Alloys.  Because of the different types of metals being welded, a molybdenum wheel is available for welding copper mesh, and its alloys.

There are two main methods of seam welding; AC Constant Seam Welding & Roll Spot Stitch welding. There are advantages to each of these technologies depending on your application and desired results.

AC Constant Seam Welding:

AC Welding uses an AC power supply to supply a constant and precise flow of energy that creates a constant seam weld. This is ideal when working to create a Hermetic seal. Also, this method works great to weld every wire within a mesh. The heat of the weld is controlled both by the speed of the wheel ( or Electrode Dwell ), and the power setting that is selected. Therefore, one can accomplish a hotter weld by slowing the electrode speed, increasing the power, or decreasing the pressure applied to the workpiece. Consequently, a seam weld can be used to create a foil pouch or pouch cell. The Sunstone AC welding systems are ideal for Pouch Cell Welding. Also, an excellent application for the AC welding system is screens and filter baskets. Filter Basket Welding can easily be accomplished using the AC welding system. Screens can be welded to backing plates and thicker materials to accomplish perfect metal screen welding.

CD Roll Spot Welding:

Roll Spot(RS) welding uses a proprietary technology with the Sunstone Capacitive Discharge (CD) welding systems. Roll Spot can be added to any level of CD welding system to accomplish a Roll Weld. CD Roll Spot Welding is simple, as the wheel rolls across the workpiece the power supply will fire welds at a set interval. This will create a stitch weld, similar to a sewing machine. As a result, the interval between each weld is dependent on power settings selected. The user simply varies the speed of the roller electrode to get the desired distance between welds. This distance can be reduced to nearly touching for a near seam weld. Additionally, the major advantage of the Capacitive Discharge Roll Spot Welding System is the cost. Strong reliable welds can be accomplished at a more affordable price than the AC welding system. If a perfect seam is not required in your application, the CD Roll Spot is a perfect fit for you.

It all starts with the power supply.

Weld metal mesh with the AC 5 kVA power supply, it is the workhorse of the system that allows for welding continuous or spot welds on all sorts of mesh, foils, and other sheet materials. With a 4 stage power adjustment, the AC 5 kVA can be adjusted to your desired power levels.


5.0 kVA Resistance Seam Welder


roll spot & seam welding handpieces

A Handpiece and roll spot accessory completes the system.

There are a number of handpieces options to fit your needs.


The most popular Roll Spot Handpiece is the PG2.  A pistol grip handpiece that has a button trigger to activate the weld. The handpiece easily fits in the user’s hand for ergonomics, and the pressure is easily applied to the electrode. Also, this handpiece is made of durable plastic, so it will not heat up and will have a long lifespan even in the most rugged industrial environments.


In addition, another great option is the PASP2 (Pictured to the Left). This handpiece is similar to the PG2 in that it has the pistol grip. Most of all added benefits of the PASP2 is that it is pressure activated. Therefore, It will activate the weld once a certain pressure is reached. This pressure can be adjusted to find the perfect match for your application. Another major feature is that the cables attach at the base of the hand, allowing your hand to freely grip and hold without hand the welding cable be in your way.


Finally, the PASP HP-Roll. This is a simple pressure actuated handpiece that allows for budget-friendly roll spot function. Includes pressure adjustment and activation.

Watch These Roll Spot Welding Examples