Austenitic Steel wire mesh screens, known for their resilience in extreme environments, were the focus of this study for developing sintered filters crucial for the safe operation of pyro valves. We present a systematic powder metallurgy approach for fabricating such meshes capable of filtering unburnt charge particles in the hot, high-pressure, and high-velocity discharge gas stream. Systematic powder metallurgy experiments with pressureless & hot-pressing routes were performed, and the process-property correlation was established. The realized samples were metallurgically characterized, and the physical, microstructure and mechanical properties of the sintered mesh were evaluated. Through device-level testing, the functionality of the filter hardware has been demonstrated, and the effect of raw material properties (wire diameters) and orientation (resulting from anisotropic Dutch-weave geometry) has been studied to derive at the optimum configuration of the sintered wire mesh. Additionally, margin demonstration tests at ± 20% charge mass under LN2 and ambient conditions were conducted towards qualification, and flow properties of the sintered mesh was evaluated through experimental and numerical methods. This paper comprehensively highlights the development process, characterization, and performance evaluation of these sintered wire mesh filters, paving the way for their crucial role in ensuring pyro valve safety.