Photo Chemical Machining for Industrial & Scientific Instruments and Controls
Photo chemical machining (PCM)—also known as photochemical etching—is a proven, production-scale process for manufacturing high-precision, burr-free metal components used in industrial and scientific instruments and control systems. By removing material through controlled chemical dissolution rather than mechanical force or heat, PCM enables complex geometries, fine features, and stress-free parts that support accuracy, repeatability, and long-term reliability.
Industrial and scientific instruments depend on precision metal components that perform consistently under demanding conditions. Whether measuring pressure, controlling flow, shielding sensitive electronics, or enabling accurate calibration, component geometry and material integrity directly affect system performance.
At Conard, photo chemical machining is used to support function-first designs for instrumentation where performance matters more than simplifying the manufacturing process.
Why Photo Chemical Machining for Instruments and Controls?
Instrumentation components are often thin, intricate, and performance-critical. Traditional fabrication methods such as stamping, laser cutting, or wire EDM can introduce burrs, distortion, heat-affected zones, or design compromises. Photo chemical machining offers key advantages for industrial and scientific instrumentation, such as:
- Burr-free edges with no secondary finishing
- No heat-affected zone (HAZ) or recast layer
- Flat, stress-free parts with uniform thickness
- Fine features and tight positional accuracy
- Excellent repeatability from prototype through production
- Digital tooling for rapid design iteration
Because PCM is a non-contact process, material properties remain unchanged—making it ideal for components that influence measurement accuracy, signal integrity, optical alignment, or fluid behavior.
Applications in Industrial & Scientific Instruments
Precision Sensor Components
Sensors are foundational to industrial automation, laboratory analysis, and environmental monitoring. PCM is widely used to produce metal components that directly affect sensor performance, including:
- Diaphragms for pressure and differential pressure sensors
- Thin metal membranes for flow, gas, and chemical sensors
- EMI/RFI shielding for low-signal measurement electronics
- Electrode patterns for electrochemical and biosensors
Analytical & Laboratory Instrumentation
Analytical instruments rely on precise metal components to ensure repeatable, accurate results. PCM is commonly used for:
- Sample handling grids and carriers
- Micro-perforated plates for filtration and separation
- Flow restrictors and micro-fluidic metal components
- Precision apertures and optical slits
- Thin metal elements for spectrometry and chromatography
Industrial Controls & Automation Systems.
Control systems increasingly integrate sensors, electronics, and thermal management into compact assemblies. Photo chemical machining supports these systems by producing:
- Encoder disks and resolver components
- Fine-feature shims, spacers, and alignment elements
- Heat spreaders and EMI shields for control electronics
- Precision springs and flexure components
Metrology & Measurement Equipment
Measurement and calibration equipment demand exceptional dimensional fidelity. PCM is used to manufacture:
- Reference scales and measurement grids
- Precision masks and alignment targets
- Thin metal gauges and calibration artifacts
- Flat components with controlled edge geometry
Scientific Research & Custom Instruments
Research and development environments often require custom components in low to medium volumes. PCM enables:
- Rapid prototyping of experimental components
- Fast design changes without tooling delays
- Small-batch production for specialized instruments
- Use of exotic or difficult-to-machine alloys
Materials Commonly Used for Instrumentation PCM
Photo chemical machining supports a broad range of metals commonly specified for instruments and controls, including:
- Stainless steels (300 & 400 series)
- Nickel and nickel alloys
- Copper and copper alloys
- Inconel® and other high-performance alloys
- Titanium
- Kovar® and controlled-expansion alloys
Conard Corp for Instruments & Controls
Designing a precision instrument component that can’t afford compromise?
Partner with Conard to apply photo chemical machining where performance, reliability, and manufacturability matter most.