— A P P L I C A T I O N
Defense
Astroseal's expanded metal mesh meets the performance and certification demands of the most critical defense platforms — from unmanned aerial systems and guided munitions to ground vehicles, ballistic protection, and naval vessels.
— M I S S I O N - C R I T I C A L M A T E R I A L S
Certified performance where failure is not an option
Defense systems operate in the most demanding electromagnetic, structural, and environmental conditions on earth. Components must perform flawlessly from first deployment to last — with zero tolerance for failure. Astroseal's expanded metal mesh has been a trusted material in defense programs for decades, serving platforms that require certified EMI shielding, energy storage, structural reinforcement, and ballistic protection.
All Astroseal materials are produced in the USA at our AS9100-certified facility in Chester, CT, and are available in OEM-qualified configurations or custom-built to program-specific requirements.
Where Astroseal Expanded Metal Mesh Is Applied
UAV & Satellites
Unmanned aerial vehicles and satellite systems depend on uninterrupted avionics performance in environments saturated with electromagnetic energy. Astroseal's expanded metal mesh provides EMI/RFI shielding for composite airframes, sensor housings, and antenna structures — protecting flight control systems, GPS receivers, and communication links from interference while meeting weight and dimensional constraints critical to unmanned platforms. In battery-powered UAVs, Astroseal's expanded metal also serves as current collector substrates and electrode support structures in primary and secondary battery systems powering remote flight controls and onboard weapon systems.
Missiles & Energetics
Composite structures used in guided munitions, rocket motor casings, and energetic system housings require EMI shielding to prevent premature ignition or system compromise from electromagnetic energy. Astroseal's expanded metal mesh integrated into these structures provides a controlled conductive barrier that safely dissipates electromagnetic energy while adding minimal weight-critical in applications where every gram affects range and performance.
Ballistic Protection
Composite ballistic protection panels used in personal armor, vehicle protection systems, and facility hardening must balance protection performance with minimum weight. Astroseal's expanded metal mesh provides structural reinforcement within composite laminates, improving inter-layer bonding strength and energy absorption — while its one-piece, single-unit construction provides superior mechanical continuity compared to multi-piece alternatives.
Ground Vehicles
Military ground vehicle composite structures — including hulls, body panels, and blast-resistant enclosures — require EMI shielding to protect onboard electronics from both external electromagnetic threats and internally generated noise. Astroseal's expanded metal mesh bonded into composite vehicle structures provides this shielding while contributing to the structural integrity of the panel. In vehicle battery systems, expanded metal serves as a current collector and electrode support for primary batteries powering GPS navigation, night vision systems, and individual weapon systems.
Submarine & Naval
Naval and submarine environments subject composite structures to saltwater corrosion, hydrostatic pressure, and persistent electromagnetic threats. Astroseal's expanded metal mesh — available with CX and CXMC corrosion-resistant coatings — provides the EMI shielding and structural reinforcement required for composite naval structures, while resisting degradation caused by long-term seawater exposure. Battery systems powering telemetry systems, on-board tool functions, and safety equipment in subsea and naval applications rely on Astroseal's expanded metal for current collector and electrode support functions in demanding primary battery configurations.