Sunstone Mesh & Filtration Welding System | Wave AC + PG2

The Complete Mesh and Filtration Welding System — AC Resistance Welding Precision for Every Wire, Every Junction, Every Seam

Wire mesh, filtration screens, and fine wire assemblies demand continuous, controlled energy that a standard spot welder cannot deliver. The Sunstone Wave AC paired with the PG2 pistol grip hand piece is the purpose-built system for this exact category of work — combining up to 2,700 amperes of digitally controlled AC welding power with the most versatile handheld delivery tool in Sunstone's lineup.

Why Mesh and Filtration Welding Requires AC — Not CD

When welding wire mesh, screens, filter baskets, or expanded metal, the challenge isn't just making a weld — it's making every wire intersection bond consistently across the entire surface. A capacitive discharge (CD) spot welder fires individual pulses. For a mesh with hundreds or thousands of wire crossings, that means hundreds of individual trigger actuations, with potential variation at each one.

The Wave AC solves this differently. In seam mode, the AC power supply flows energy continuously through the electrode as it rolls across the surface. Every wire intersection the electrode contacts receives a weld. The operator guides the PG2 hand piece across the mesh; the Wave AC handles the energy delivery. The result is a uniform, fully welded mesh surface — not a series of individual spots.

For filtration components — filter bodies, screen-to-housing bonds, mesh baskets, and hermetic filter enclosures — this continuous welding capability is what makes the assembly structurally sound and leak-resistant in service.

What's in This Bundle

1. Sunstone Wave AC — Advanced AC Resistance Welder

The Wave AC is Sunstone's most advanced AC resistance welder, built on a redesigned transformer and fully digital control architecture. It delivers a continuous, controlled flow of AC energy — from 225A to 2,700A — with precise phase control that gives the operator fine-grain adjustment over how much heat enters the workpiece on every pass.

Key capabilities for mesh and filtration welding:

• Seam mode — continuous energy delivery for rolling seam welds across mesh, screen, and filter surfaces. The welder flows current as long as the trigger is held and the electrode is moving
• Roll-spot mode — discrete weld spots generated at intervals as the roller electrode travels, for applications requiring controlled spot spacing rather than a continuous seam
• Phase adjustment from 40–100% — dial in precise heat input for thin or delicate wire gauges where excessive energy would burn through or deform the mesh
• Half cycle mode — the lowest energy setting, for the finest wire gauges and most heat-sensitive materials
• 10-inch color touchscreen with real-time waveform visualization — see exactly how energy will be delivered before you weld, and adjust parameters on the fly
• Up to 100 saved weld schedules — store parameters for every mesh gauge, wire diameter, and filtration application you run regularly
• 200VAC–250VAC single-phase input required

2. Sunstone PG2 — Pistol Grip Hand Piece

The PG2 is Sunstone's standard pistol grip welding hand piece, and the correct delivery tool for roll-spot and seam welding applications with the Wave AC. Its button trigger initiates the weld, and its 3/8"x20 threaded electrode mount accepts a range of interchangeable electrodes — including the roller (wheel) electrode that makes continuous seam welding possible.

PG2 specifications:

• Trigger: Button trigger on pistol grip body
• Electrode mount: 3/8"x20 threaded, accepts all compatible Sunstone threaded electrodes
• Cable: 1 AWG welding cable
• Weight: 5 lb (2.26 kg)
• Dimensions: 6.5" x 6.5" x 1.25"
• Compatible welders: Sunstone CD, DC, and AC welders — making it a versatile hand piece beyond this bundle

The PG2 can also be configured with a standard pointed electrode for single-probe spot welding when seam mode isn't required — giving you flexibility to handle both rolling seam work and conventional spot welds from the same hand piece.

Note: The roller (wheel) electrode for seam welding is not included in this bundle. See our compatible [Sunstone EL-Roll Wheel Electrode] for the correct roller electrode to pair with the PG2 for seam welding applications.

What This System Welds

The Wave AC + PG2 combination is purpose-matched for a specific and important category of precision fabrication work:

Wire mesh and screen welding — bonding every wire intersection across a mesh surface. Used in filtration, shielding, safety screens, and architectural metalwork. The rolling seam mode ensures every wire contact point is welded without the operator having to trigger each one individually.

Filter basket and body assembly — welding mesh to frames, seams, and housings in industrial, HVAC, automotive, and food processing filtration components. The continuous energy delivery ensures a leak-resistant bond across the entire seam length.

Expanded metal welding — bonding expanded metal sheets to substrates or frames in industrial, construction, and aerospace applications.

Hermetic filter enclosures — sealed filter assemblies for medical, laboratory, and precision instrumentation applications where the filter housing must be completely sealed.

Fine wire welding — joining individual fine wires or wire-to-substrate bonds in electronics, sensors, and specialty fabrication. The Wave AC's phase control allows precise, low-heat energy delivery that preserves fine wire geometry.

Faraday cages and EMI shielding — welding mesh shielding enclosures and EMI screen panels for electronics and defense applications.

Multi-layer filter design — bonding multiple mesh layers together in sequence for complex filtration media assemblies.

Choosing Your Configuration

This bundle has one primary configuration variable: Wave AC power level.

The Wave AC's power steps (1–4) are selectable through the touchscreen interface. For most mesh and filtration welding — standard stainless steel or nickel wire mesh in typical industrial gauges — Power Level 1 or 2 at moderate phase settings provides the right combination of energy and sustained duty cycle. This allows long seam runs without thermal interruption.

For finer wire gauges (thinner than 0.1mm), use a lower phase percentage at Power Level 1 or engage half-cycle mode for maximum heat control.

For heavier wire gauges or thicker filter media requiring more energy per contact point, step up to Power Level 3 or 4 with a higher phase setting — but monitor duty cycle limits, as sustained high-energy output reduces the maximum continuous run time before the thermal protection engages.

If your application involves a specific wire gauge, mesh aperture, or filtration material you're unsure about, contact our technical team before purchasing. Matching energy settings to material is the most important setup decision for mesh welding quality.

A Note on Water Cooling for Extended Seam Runs

For production environments requiring very long continuous seams or extended high duty-cycle operation, the standard PG2 hand piece has thermal limits that will require pauses between seam runs. Sunstone offers a water-cooled version (PG2W) and a water-cooled cable system (PG3W) for these applications. If your production requires continuous seam welding over long distances without pause, contact our team to discuss whether the water-cooled configuration is the right fit for your operation.

Why Buy This Bundle From The Maker's Chest?

75-Day Return Window — more than double Sunstone's 30-day return window. If the system doesn't perform as expected on your specific mesh or filtration application, you have 75 days to return it — giving you real time to validate it in production conditions.

Expert USA-Based Technical Support — mesh and filtration welding involves real setup knowledge: phase settings, electrode selection, seam speed, duty cycle management for your specific wire gauge and material. Our team can help you work through parameters for your application.

Dual Lines of Support — both our in-house technical team and Sunstone's own resources are available to you on a single purchase.

Authorized Sunstone Reseller — genuine product, full manufacturer warranty, backed by our additional support layer.

Frequently Asked Questions

Why use an AC welder for mesh welding instead of a CD or DC welder? AC welders flow energy continuously while the trigger is held, making them ideal for seam and roll-spot welding across mesh surfaces. A CD welder fires a discrete pulse per trigger actuation — effective for individual spot welds, but not designed for continuous seam delivery. For mesh welding where every wire intersection needs to be bonded, the Wave AC's seam mode is the right technology.

What is the difference between seam mode and roll-spot mode on the Wave AC? In seam mode, the Wave AC delivers continuous energy as long as the trigger is held and the electrode is rolling. Every point of electrode contact receives energy — producing a true continuous seam weld. In roll-spot mode, the machine fires discrete weld pulses at set intervals as the electrode rolls, producing a series of evenly spaced spot welds along the travel path. Seam mode is best for hermetic sealing and full mesh bonding; roll-spot is better when controlled spot spacing is needed rather than a continuous bond.

Is the roller (wheel) electrode included in this bundle? No — the PG2 hand piece accepts threaded electrodes, but the roller electrode is sold separately. You'll need a compatible wheel electrode (such as the Sunstone EL-Roll) to perform rolling seam welds. Contact our team when ordering to ensure you have the correct electrode for your application.

What wire gauges and material thicknesses can this system weld? The Wave AC is designed for materials from approximately 0.05mm up to 0.75mm in thickness, depending on metal type and orientation. For mesh welding, this covers the vast majority of industrial wire gauges used in filtration, shielding, and fabrication applications. Thicker materials in the 1–1.25mm range can be welded with appropriate electrode and power settings. Contact our team with your specific wire gauge for a recommendation.

Does the Wave AC require special electrical installation? Yes. The Wave AC requires a 200–250VAC single-phase power supply — it is not compatible with standard 120V North American outlets. Most manufacturing and production facilities already have 208V or 240V single-phase circuits. If yours does not, a licensed electrician will need to install a dedicated circuit before use.

Can the PG2 be used for spot welding as well as seam welding? Yes. The PG2 accepts both pointed/standard electrodes for conventional single-probe spot welding and roller electrodes for seam welding — making it a flexible hand piece for shops that run both types of work. The Wave AC also supports single-cycle spot weld mode in addition to seam mode.

What maintenance does this system require? The PG2 hand piece requires regular electrode inspection and replacement when the electrode tip shows wear or contamination. For the Wave AC, primary maintenance includes monthly cleaning of cooling vents, quarterly visual inspection, and annual cable checks. Keeping electrodes clean and properly shaped is the most direct factor in consistent weld quality on mesh applications.

What is your return policy? 75-day returns. If the system doesn't work for your application, reach out and we'll take care of you.

Bundle includes: Sunstone Wave AC Resistance Welder + Sunstone PG2 Pistol Grip Hand Piece Note: Roller electrode for seam welding sold separately Brand: Sunstone | Wave AC Input: 200–250VAC Single Phase