Abstract: A process is disclosed for fabricating a biocompatible mesh screen structure for bonding to a prosthetic substrate. The process comprises providing from four to eight layers of a mesh comprising a titanium alloy and subjecting the layered structure to a temperature below the beta-transformation temperature of the alloy and a pressure of about 1300 to 1500 psi. The heating and pressing are carried out in a furnace maintained at a temperature of about 1600.degree. to 1725.degree. F., which is evacuated to a vacuum of less than about 10.sup.-4 torr. The process of the invention provides a product retaining the strength of the alloy and having a well-characterized pore structure. Further, the layered mesh composite may be bonded to a thin substrate and readily formed into complex shapes.