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  1. What are the Problems of Photo Etching?

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    The primary problem is a case of multiple identity disorder: photo chemical machining, PCM, photo chemical etching, photo etching, chemical etching and chemical machining all refer to the same process. We don’t wonder why you are confused. In speech, I always call the process “photo etching.” However, if you want to be found, you have to be known all the different ways.

    There are three additional, similar sounding processes that are NOT photo etching. 

    • Electro chemical etching (sometimes called electrolytic etching) is a process used for part marking on metal parts. 
    • The MetalPhoto process utilizes pre-treated aluminum panels to create nameplates and identification products.
    • Chemical milling is a process used to modify parts by selectively removing metal from specific areas. Chemical milling is most often used on airframe components to reduce weight. In this context, chemical milling may be subject to Nadcap checklist 7108/5. Nadcap (formerly NADCAP, the National Aerospace and Defense Contractors Accreditation Program) is a global cooperative accreditation program for aerospace engineering, defense and related industries. Nadcap covers a range of special processes with uniform standards. Photo chemical etching is not subject to Nadcap because the etching process does not alter the properties of the material.

    The biggest problem with chemical etching is that it is not well known and is little understood.

    Photo etching is a metal fabricating technique that fits in a spectrum of processes that include metal stamping, CNC punching, laser and water-jet cutting  and wire EDM. The end result of all of these processes is flat metal parts. (Yes, I know, formed parts can be produced by stamping with compound dies, but let’s just stick with the basics.) 

    Stamping and punching are processes that require hard metal tooling to cut parts from sheets of metal. Laser and water jet use narrow beams of focused energy. In the case of the laser, the energy comes from colimated light, and the water jet uses a pressurized abrasive slurry. Wire EDM uses a wire electrode to burn the parts out of metal.

    One of the chief advantages of photo chemical etching when compared to these other processes is that photo etched parts do not acquire any thermal or mechanical stresses during fabrication. The unwanted metal is dissolved by the etchant and rinsed away.

    Another problem with photo chemical machining is that it is a relatively rare process. There are only about 100 PCM shops in the country and barely a few hundred globally. Compare that to about 2,000 metal stamping shops just in the US. Photo etching is often a better solution to fabricating flat metal parts, but too few people are familiar with the process. This video provides a 2-minute overview of the photo etching process: http://www.iplayerhd.com/player/ConardCorp

    We also have to overcome the problem of the misperception about photo etching and the environment. Photo chemical etching is closely monitored by environmental protection departments in every state where there are PCM shops. We take environmental responsibility very seriously. We have state of the art water treatment facilities. Our process waste water is cleaner than the municipal water supply. You can drink it. We actually have to clean the city water before we can use it in the photo etching process.

    Despite the problems, photo etching is a versatile and cost effective solution for producing 

  2. American manufacturing news roundup – May 2015

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    Here are a few stories about the booming U.S. manufacturing and tech sectors that caught our eyes over the last month.

    We’ve heard several exciting stories in the American manufacturing and tech sectors over the last month. Here are a few that really caught our eyes as we make our way through May.

    Manufacturing jobs returning to the U.S. at a record pace
    The level of optimism surrounding U.S. manufacturing has been rising steadily over the last few years, but there’s a new milestone to celebrate. It was recently announced that in 2014, the number of manufacturing jobs returning to the U.S. from overseas was greater than the number of positions outsourced, MarketWatch reported.

    About 60,000 manufacturing jobs came to the U.S. last year as a result of reshoring or foreign direct investment in our domestic markets. This is a big jump from where we were about a decade ago, when only 12,000 jobs were added in 2003. On the other side, only 50,000 jobs were offshored last year, down from the 150,000 sent overseas in 2003. This reversal has been a decade in the making and represents a trend back to domestic manufacturing.

    “The trend in manufacturing in the U.S. is to source domestically,” Harry Moser, president of the Reshoring Institute said to MarketWatch. “With 3 [million] to 4 million manufacturing jobs still offshore, we see huge potential for even more growth.”

    “About 60,000 manufacturing jobs came to the U.S. last year.”

    GM prepares to invest in its workforce as manufacturing jobs rise
    General Motors recently announced that it was planning a new round of investments in its Pontiac Metal Center located near Lansing, Michigan, the Detroit Free Press reported. This is due to the rising level of manufacturing employment occurring throughout the country. The news source also noted that expansions were also slated for a Cadillac, Yukon and Tahoe plant near Arlington, Texas.

    A study from the Center for Automotive Research found that GM provided 51,910 manufacturing jobs at the end of 2014, an increase of 1.8 percent from 2013. Of that number, 16,120 were in Michigan, Ohio had 9,710, Indiana had 7,730 and New York rounded it out with 4,360. While the workforce hasn’t reached pre-recession levels just yet, the growth here is an encouraging sign for the recovering auto industry and the American economy as a whole.

    Overall manufacturing employment is on the rise, and that bodes well for the automotive industry.
    Overall manufacturing employment is on the rise, and that bodes well for the automotive industry.

    Connecticut manufacturer recognized for excellence and commitment to “Made in America”
    A local manufacturer has been drawing attention from some high places. The Bristol Press reported that Senator Chris Murphy recently named The Lighting Quotient Inc., a Connecticut-based manufacturer of industrial lighting applications, as a “Monday Manufacturer” – a title that recognizes excellence in manufacturing as well as a dedication to keeping the industry in Connecticut. 

    The Lighting Quotient has adapted to changing business conditions by producing high-end lighting applications that meet strict sustainability goals and environmental requirements. The company’s products have been featured in the White House, the Thomas Jefferson Memorial, the Olympic Visitors’ Center and other prestigious sites. Best of all, they’ve done it the right way – hiring local workers, sourcing local materials and working with over 100 vendors in Connecticut.

    “Momentum is building and the time is imminent that state government and all of Connecticut manufacturing stakeholders draw a line in the sand and not allow more of our manufacturing power and economic health be taken out of state,” said Allison Schieffelin Walker, chairwoman and CEO of The Lighting Quotient. “It’s our mission to keep good manufacturing jobs here in Connecticut.”

    The rubber is ready to meet the roads for Google’s self-driving cars
    Google’s self-driving cars have been garnering headlines for years now, and for the first time, they’re ready to leave the safety of the test track and start driving on public roads, according to IndustryWeek. These cars, which represent the leading edge of self-driving automobile technology, could have a major impact on the tech and automotive sectors moving forward.

    The cars are equipped with sensors and Internet-connectivity that control the critical functions of the vehicles. Google’s engineering and design team has been at the forefront of this emerging technology, and success with this experiment could lead to a major cultural, technological and economic shift as self-driving vehicles come to prominence and change the face of transportation.

  3. American manufacturing news roundup – March 2015

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    The first quarter of the year may be coming to an end, but the American tech and manufacturing sector isn’t slowing down.

    The first quarter of the year may be coming to an end, but the American tech and manufacturing sector isn’t slowing down. Over the past month, we’ve seen some incredible changes that will push the boundaries of the industry, including one story that is very near and dear to our hearts.

    White House proposes over $600 billion budget for National Network For Manufacturing Innovation in 2016
    The Obama administration proposed a substantial increase in the National Network For Manufacturing Innovation’s 2016 budget. According to Manufacturing and Technology News, the total amount for the new NNMI budget – across all of its departments – comes to $608 million for the year. The funding will come from the Departments of Defense, Energy, Commerce and Agriculture. Among the institutes receiving notable budget increases are:

    • The Digital Manufacturing and Design Innovation Institute will receive $27 million in 2016, up from $14 million in 2015 and $6 million in 2014.
    • The Lightweight and Modern Metals Manufacturing Innovation Institute is due for $27.6 million in 2016 up from $13 million in 2015.
    • The Flexible Hybrid Electronics Manufacturing Innovation Institute is set to receive $29.7 million in 2016, up from $9.9 million in 2015

    In addition to bulking up the budgets of the nine existing institutes in the network, the new budget proposed the creation of seven more. Eventually, the administration hopes to transition the NNMI budget from being a “discretionary” expenditure to a “mandatory appropriation” – a move that will hopefully cement these important organizations’ place in the tech and manufacturing industry.

    The massive budget increase for the NNMI shows an increasing commitment to American manufacturing and innovation.
    The massive budget increase for the NNMI shows an increasing commitment to American manufacturing and innovation.

    Toyota believes its hydrogen-powered car can reach diesel prices within a decade
    We’ve seen a lot of excitement about Toyota’s new hydrogen-powered car, the Toyota Mirai. Slated for release later this year, the car looks like the next step in the trend toward reducing and eliminating automobile emissions for good. Best of all, recent announcements from the company suggest that the car will be within the reach for most consumers within a few years.

    According to Manufacturing.net, Katsuhiko Hirose, the head of Toyota’s hydrogen fuel cell division, announced that the car will debut with a $57,500 price tag. This is better than previous forecasts that predicted the entry price of the car would be $60,000, and it blows the project’s initial estimates of $100,000 right out of the water.

    Hirose believes that within 10-15 years, the hydrogen car will be similar in price to a diesel car. Other Toyota officials think it will take half that amount of time.

    Rolls-Royce gives us a glimpse into the future of plane engines
    Late in February, Rolls-Royce unveiled its new designs for a fuel-efficient airplane engine that could be a part of the civilian aircraft of the future. Industry Week reported that the new design builds on the successful Trent XWB engine, which has been the only engine used in the popular Airbus A350 passenger planes.

    Rolls-Royce stated that the new engine, named Advance, will use 20 percent less fuel than the original Trent engine, and will lead to a notable drop in carbon emissions. The manufacturer expects that the engine will be ready for use by the end of the decade. Even then, they already have a more energy-efficient model in the works, known as the UltraFan, could be ready by 2025.

    “The additive processes have redefined what manufacturers thought was possible.”

    Additive manufacturing in Connecticut
    Additive manufacturing has taken off throughout the industry due to its ability to create new designs and augment pre-existing designs and finished parts.

    According to the Hartford Business Journal, Rainer Hebert, director of the UConn-Pratt & Whitney Additive Manufacturing Innovation Center, has stated that the use of additive technology in production could position Connecticut as an emerging additive manufacturing leader.

    The additive processes, like 3D printing and electroforming, have redefined what manufacturers thought was possible by allowing them to use new materials to make complex parts that elude conventional fabrication methods.

    “At the Connecticut Center for Advanced Technology’s (CCAT) Advanced Manufacturing Center, we’re using additive directed energy deposition technology to help companies in the medical, energy, aerospace and defense industries develop new products, repair and enhance existing parts and research new materials faster and at lower costs than ever before,” Tom Maloney, chief technology officer of the Connecticut Center for Advanced Technology, wrote in an article in the HBJ.

    It’s exciting to see the additive processes get some recognition that will allow OEMs throughout Connecticut and beyond to take advantage of their benefits. We’ve been a part of that field for awhile now, and we know that OEMs who need to make their parts and products smaller can greatly benefit from additive manufacturing.

  4. American manufacturing news roundup – February 2015

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    Google LogoEven though we’re only halfway through February, we’ve seen enough good news coming out of the American manufacturing sector to last us the rest of the month and beyond.

    One of the most exciting themes is just how vital manufacturing and technology are to the renewed growth of the U.S. economy.

    In this roundup, we’ll see how the U.S. is becoming a global leader in aerospace manufacturing, the growing role of the “advanced industries” in the growth of the U.S. economy, how investments in transportation infrastructure could create thousands of jobs and how an entire state is working to get students interested in manufacturing and STEM fields.

    “It appears that the aerospace industry is investing more in U.S.-based production now.”

    The U.S. is becoming a hotbed for aerospace manufacturing
    In a major victory for American job reshoring efforts, it appears that the aerospace industry is investing more in U.S.-based production now, after a decade in which the majority of those jobs were sent to China, Reuters reported.

    According to consultancy ICF International, from 2000 – 2012, aerospace investments flowed into China, Brazil, Mexico and India. But in the three years since, data has shown that the bulk of the investments in the industry have come to the U.S.

    “The U.S. at this point in time has become the hot spot in aerospace manufacturing,” Kevin Michaels, a vice president at ICF International, said at the annual Pacific Northwest Aerospace Alliance conference this week. “Comparative advantage is a fleeting thing. Three years ago it looked like everything was heading to China. Now that’s changed.”

    Manufacturing makes up 35 of the 50 “advanced industries”
    A new report from the Brookings Institute has brought renewed attention to the importance of America’s “advanced industries” sector.

    Throughout the recession, job growth and incomes for many workers stayed stagnant. But as the U.S. recovers, it’s become clear that the way forward for American workers and the nation as a whole is in the continued growth of these advanced industries.

    An advanced industry is characterized by its heavy involvement in technology research and development and STEM workers. By the Brookings Institute’s definition, the sector includes 50 industries ranging from manufacturing to energy to engineering and design services

    This is a broad view of the U.S. tech sector, but as the report’s authors wrote, the dynamic nature of these 50 industries is what will revitalize the U.S. economy and put the country on the path to sustainable, organic growth.

    Manufacturing, in particular looks to play a major role in this sector’s growth moving forward, as its various sectors make up 35 out of the 50 industries that the report considers advanced. But we don’t have to wait to see results: According to the report, the advanced industries have added almost one million jobs with employment and output growth rates 1.9 and 2.3 times higher, respectively, than every other economic sector.

    Manufacturing is the heart and soul of the "advanced industries," and where we can expect to see sustained growth as high-tech sectors take a central role in the U.S. economy.
    Manufacturing is the heart and soul of the “advanced industries,” and where we can expect to see sustained growth as high-tech sectors take a central role in the U.S. economy.

    U.S. manufacturing could get a big boost from new rail system investments
    American manufacturing could be in for a windfall if the U.S. government chooses to invest in and repair the aging rail systems throughout the country, BlueGreen Alliance and Environmental Law & Policy stated in a recent joint report.

    While the U.S. rail system is in disrepair, the volume of passengers it’s expected to accommodate has increased dramatically – taken together, commuter, light and heavy rail saw a 75 percent increase in passenger numbers since 1995, the report stated.

    Right now, there are more than 750 companies in at least 39 states that are manufacturing component parts for passenger rail and transit, including railcar and locomotive producers. And in the Midwest and mid-Atlantic alone, there are 542 companies manufacturing sub-components, materials, track and infrastructure, and providing repair and remanufacturing.

    “Every $1 billion invested in U.S. transportation infrastructure would lead to roughly 21,000 new jobs.”

    Altogether, the rail manufacturing industry supports about 90,000 jobs, the Alliance for American Manufacturing reported. The news source found that every $1 billion invested in U.S. transportation infrastructure would lead to roughly 21,000 new jobs.

    Georgia schools launch initiative to encourage students to get into manufacturing
    We love hearing about when an individual school or district implements programs to get kids interested in STEM fields. So you can imagine how exciting it is when an entire state does it all at once.

    According to the Gainesville Times, every single one of the 932 public middle and high schools throughout the state of Georgia will be the first schools to take part in a nationwide initiative that encourages students to look at careers in manufacturing.

    This month, Governor Nathan Deal and celebrity host of the “Made in America” television show, John Ratzenberger, will announce the statewide enactment of the National Educational Initiative, which will help bolster the image of manufacturing as a career choice and help students develop skills to get into the field.

    “We have a person at the district level that is dedicated to helping us pursue not only STEM, but STEAM, which is science, technology, engineering, arts and mathematics,” Wanda Creel, Gainesville City Schools superintendent, said to the Times. “And many of our schools have an emphasis on STEM. For example, Gainesville Exploration Academy has a STEM lab.”

  6. American manufacturing news roundup

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    From new innovations, to blockbuster investments, to more youth outreach from the STEM fields, to encouraging hiring trends – it’s clear that American ingenuity and progress are in full swing as 2015 gets underway.

    The tech and manufacturing sectors in the United States started this year with a bang on several fronts. From new innovations, to blockbuster investments, to more youth outreach in the STEM fields, to encouraging hiring trends – it’s clear that American ingenuity and progress are in full swing.

    It’s tough to pick just a few stories out of the bunch to highlight in our monthly roundup. But here are a few that really caught our eye and, as always, made us proud to be a part of the incredible story that American manufacturing is writing.

    Toyota and Tesla make their fuel cell patents free
    At the 2015 Consumer Electronics Expo, Toyota announced that it would follow Tesla’s lead in making its hydrogen fuel cell patents available royalty-free, LiveScience reported.

    The automaker said it will make 5,600 of its fuel cell patents free through 2020 for other automobile manufacturers that are working on producing fuel cells. Parts suppliers will also have access to the patents.

    “The first-generation hydrogen fuel cell vehicles, launched between 2015 and 2020, will be critical, requiring a concerted effort and unconventional collaboration between automakers, government regulators, academia and energy providers,” Bob Carter, Toyota’s senior vice president of automotive operations, said in a speech at CES.

    Both Toyota and Tesla have expressed hope that by making their patents free, they can jumpstart innovation in the fuel cell industry as part of a greater effort to make emission-free vehicles.

    Google and Fidelity invest in SpaceX​’s Mars endeavors
    If there’s one company here in America that is inspiring everyone to reach for the stars, it has to be SpaceX, a manufacturer of spaceships and other space-related equipment. The company, headed by billionaire Elon Musk, has never shied away from striving for seemingly impossible goals and pushing the envelope beyond what many thought would be impossible for a private enterprise.

    In an effort to put the company in a position to keep innovating, tech and financial giants, Google and Fidelity, have jointly invested $1 billion in SpaceX, according to a report from Manufacturing Business Technology.

    While it’s unclear exactly what the company’s plans are at the moment, Musk has stated that he wants to send people to Mars within the next 12 years and eventually build a livable city on the planet.

    The American tech and manufacturing sectors have produced no shortage of inspiring stories in just the last month alone.
    The American tech and manufacturing sectors have produced no shortage of inspiring stories in just the last month alone.

    Detroit lightweight materials manufacturing institute opens
    The American Lightweight Materials Manufacturing Innovation Institute has finally opened its doors in Corktown, a Detroit neighborhood. The project was spearheaded by Ohio State University, EWI, a Columbus-based manufacturing and research consulting nonprofit, and the University of Michigan, Columbus Business First reported.

    The $148 million institute will be open to groups and companies who want to partner with the three organizations as well as one another with the goal of developing new technology surrounding the fabrication of lightweight materials.

    What’s most exciting is that innovation will breed manufacturing jobs here. According to the news source, the group estimates that it’s efforts will lead to the creation of 10,000 jobs related to the casting, machining and metalworking for lightweight materials.

    “What’s most exciting is that innovation will breed manufacturing jobs.”

    Manufacturing executives are optimistic about hiring this year
    According to PricewaterhouseCooper’s latest Manufacturing Barometer survey, manufacturing executives were optimistic about hiring and the economy as a whole in 2015. The results of the survey, featured on Manufacturing.net, showed that 68 percent of respondents were optimistic about the U.S. economy’s growth for the coming year, up from 57 percent from the previous quarter’s survey.

    Not only were the respondents excited for America’s economic prospects as a whole, they stated that they are looking forward to a great year in their own operations. According to the survey, 60 percent of the respondents said they planned to increase their workforces this year, 43 percent expected to receive new capital investments and 52 percent planned to widen their product and service offerings.

    More opportunities for students interested in STEM
    The Citizen’s Bank Foundation donated $50,000 to develop an initiative through which businesses can partner with public schools to encourage participation in STEM classes and work-based study programs. The grant was awarded to the Pathways in Technology Early College High School program at Troy High School in New York, Times Union reported.

    The program, known as P-TECH, is a three-state program in New York, New Jersey and Connecticut that allows students to engage in work-based learning with a corporate partner. This will kill two birds with one stone: The students can learn valuable skills to help them land a great paying job right out of school, while the companies who participate will get a ready-made workforce for when their older employees retire.

    “The business community recognizes the urgency in closing the middle skills gap, and that jobs in the STEM field play a major role in driving the state’s economy,” Heather C. Briccetti, president and CEO of The Business Council of New York State and a member of the P-TECH Leadership Council, said to the Times Union.

  7. Aluminum: Why Etchers (except us) hate it

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    Aluminum is a light and versatile metal. However, it has a couple of characteristics that give etching houses fits. It is highly reactive and will etch in both acids and bases. Common photoresist film is designed to repel acid, but to remove it you need to use a fairly high Ph caustic solution. And, oh darn, that etches aluminum, too. So, say bye-bye to dimensional tolerances. For many etchers, the headache isn’t worth it. (And, shhh, don’t tell anybody… but sometimes they come to us for aluminum.)

    (more…)

  9. 6 Reasons Why Engineers Should Consider Photo Etching

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    For design and development engineers today, design for manufacturability is a key part of the process. In the “good old days,” when I was in purchasing, the drafting department would deposit a mountain of blue prints on my desk and it would be my job to find suppliers who could produce the parts. Often times, the specifications on the parts exceeded the capabilities of the production equipment. The designers wanted tolerances and features that could not be achieved with the technology of the day.

    As CAD has become more capable and informed with respect to the “output” systems (CNC machining centers and such), the gap between want and can do is shrinking. The problem we in the metal etching industry face is that the CAD and solid modeling systems are completely blind to the capabilities of our process.

    Here are key reasons why designers and engineers should consider photochemical machining as a preferred option for fabricating precision metal parts:

    1. No Burrs or Mechanical Deformation: By definition, stamping and punching are shearing metal directionally and burrs are an inescapable consequence. Some alloys will be cold worked at the shear point and may require subsequent annealing. Photo etching simply dissolves the unneeded metal. We call it “stress free machining.”

    2. No Thermal Distortion:  Lasers, plasma and wire EDM can impart significant heat at the cut line. Plasma cutters operate at 25,000 degrees F. Lasers vaporize the metal in their path. EDM actually burns the metal with an electrode. These processes can alter the characteristics of the metal alloys. By contrast, in our process, the highest instantaneous temperature is in the laminating process at 165 deg F for seconds, and the etching lines run at 125 deg F. McDonald’s serves its coffee hotter than that.

    3. Simultaneity:  Both stamping and etching can produce multitudes of holes simultaneously, but punching requires multiple strikes and the linear processes (laser, plasma and EDM) must address each hole one at a time. The more holes required, the more expensive the stamping dies become. But, with a phototool, whether it’s one hole or a million holes, the cost of the tool doesn’t change and is generally less than $300.

    4. Cycle Time:  Stamping is obviously the quickest of the lot. In a comparison we recently did of the part pictured below, stamping could produce 2400 parts per hour. The same part would be 800 parts per hour in chemical machining, and 80 parts per hour in a laser.

    5. Design Changes are Easy: All we need is a new CAD file and a new piece of film: less than $300 and done in 24 hours.

    CCSTAR_crop

    6. Cost Effectiveness:  Here’s a cost comparison for the part pictured above which is 2.7 inches in diameter and produced in .020″ stainless.

    Photo EtchingMetal StampingLaserWater Jet
    Tooling$235$10-$13,000N/AN/A
    1000$2.03$3.85$2.03$3.50
    5000$1.96$1.95
    10000$1.81$1.80

    For more in depth information:

    Comparing Metal
    Fabricating
    Technologies Guide
    FREE Download!

  10. 5 Key Problems of Photo Chemical Machining

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    The three biggest problems with photochemical machining are that it is not well known; it is little understood; and it has too many names. Here’s a major case of multiple identity disorder: photo chemical machining, PCM, photo chemical etching, photo etching, chemical etching and chemical machining all refer to the same process. 

    There are three additional, similar sounding processes that are NOT photo etching.

    • Electro chemical etching (sometimes called electrolytic etching) is a process used for part marking on metal parts. 
    • The MetalPhoto process utilizes pre-treated aluminum panels to create nameplates and identification products.
    • Chemical milling is a process used to modify parts by selectively removing metal from specific areas. Chemical milling is often used on airframe components to reduce weight. In this context, chemical milling may be subject to Nadcap checklist 7108/5. Nadcap (formerly NADCAP, the National Aerospace and Defense Contractors Accreditation Program) is a global cooperative accreditation program for aerospace engineering, defense and related industries. Nadcap covers a range of special processes with uniform standards.

    Photochemical etching is not subject to Nadcap because the etching process does not alter the properties of the material.

    Another problem with photochemical machining is that it is a relatively rare process. There are only about 100 PCM shops in the country and barely a few hundred globally. Compare that to about 2,000 metal stamping shops just in the US. Photochemical etching is often a better solution to fabricating flat metal parts, but too few people are familiar with the process.

    We also have to overcome the misperception about etching and the environment. Today, all-aqueous chemistries are used. PCM is closely monitored by environmental protection departments in every state where there are PCM shops. We take environmental responsibility very seriously. We have state of the art water treatment facilities. Our process waste water is cleaner than the municipal water supply. We actually have to clean the city water before we can use it in the etching process.

    Photo etching is a process that involves a considerable suite of specialized facilities and equipment. It’s surprising how often we receive inquiries from people who “want to buy a photo etching machine.” It’s not a photocopier.

    Photo etching is a metal fabricating process that fits in a spectrum that includes metal stamping, CNC punching, laser, plasma and water-jet cutting, and wire EDM. The end result of all of these processes is flat metal parts. Stamping and punching are processes that require hard metal tooling to cut parts from sheets of metal. Laser, plasma and water jet use narrow beams of focused energy. In the case of the laser, the energy comes from colimated light, and the water jet uses a pressurized abrasive slurry. Plasma uses a beam of highly energized gas. Wire EDM uses a wire electrode to burn the parts out of metal.

    Stamping and punching create mechanical stresses and burrs on the metal. Laser, plasma and EDM generate thermal stresses which may alter the characteristics of the metal.

    Among the advantages of etching is that etched parts do not acquire any thermal or mechanical stresses during fabrication. The unwanted metal is dissolved by the etchant and rinsed away. We think of it as “stress free machining.”

    Thousands of companies in dozens of industries rely on etched metal components in their products.

    For more information:

    2 Minute Etching Video

    Design Considerations
    for Photo Etching

    Or:

    Request a Quote