Photo etching has a number of design features that make it a desirable fabrication method for precision metal parts.
In most industries, there is a strong demand for precision metal parts. In many cases, these parts also have to be brought down to the micro level – with features that are a few thousandths of an inch. Photo etching has a number of process capabilities that make it a desirable fabrication method for these purposes. (more…)
The first Friday of October – known as National Manufacturing Day – kicks off what is now considered Manufacturing Month here in the U.S. All throughout the month, manufacturers and educational institutions will lead discussions and panels about the state of U.S. manufacturing now and in the future. The American manufacturing industry has never been as exciting as it is today, with so many different technological and industrial innovations converging to change the sector as a whole.
Photo etching is unique in this regard: Even though it’s a fabrication method that’s been around for decades, it is extremely well-suited to meet the needs of modern manufacturing. Here are three reasons why photo etching should be included in any celebration of American manufacturing this month.
1. Perfect for “micro” manufacturing One of the biggest trends in the industry today is the rise of micromanufacturing. In many different verticals, from microelectronics and medical equipment to RF and microwave, finished products are shrinking at a rapid rate. That means the component parts inside them must get smaller without sacrificing performance.
The limitations of conventional fabrication methods, such as stamping, laser cutting and wire EDM, become more apparent at such miniscule dimensions. They often leave thermal and mechanical distortions that affect the tolerances of the part. It’s not uncommon to see recast layers caused by extreme heat or burrs left behind by cutting – not good when the final part can be completely thrown off by even the slightest aberration.
Photo etching is able to overcome these problems by being fairly benign in its interaction with the material – there is no “brute force” cutting or extreme temperatures. The process utilizes what is known as a phototool, which is a stencil of the final part printed on a sheet of metal in a layer of photoresist. The etchant (usually ferric chloride) dissolves the exposed metal, leaving only the final part.
This allows for an accurate, repeatable process. Drawing block tolerances of +/-.005″ are achievable on metals up to .032″ thick. For metal over .005″ thick, minimum dimensional tolerances are +/- 15 percent of metal thickness. Location tolerances will be within +/-.001″ of drawing nominal.
Micromanufacturing is one of the most exciting trends in the industry today, yet an older process may be the best option to meet those needs.
2. Relatively inexpensive In industries like electronics manufacturing, the prices of final products are continuing to decline. OEMs need to find ways to cut their costs without hindering their products’ quality.
Conventional methods generally get very expensive at high production volumes due to tooling and setup costs. These costs get even higher if the OEM needs to make a design change, as all new tooling must be created to accommodate it.
Phototools, the foundation of the etching process, generally cost $300 or less and can be ready within 48 hours. They can also be easily regenerated for multiple production runs, so your costs won’t increase dramatically just because your desired production volume is high.
3. Can work with a variety of materials Not only are most products getting smaller, they are also getting lighter. Consider the example of an airplane manufacturer – it must include a full array of electronics and communications equipment without adding excessive weight to the plane. This is leading manufacturers to experiment with new materials that allow them to reduce the weights of their final products. Again, this must be done without affecting performance.
One metal that is expected to become more common is aluminum. It’s lightweight and versatile, but is difficult to work with due to its sensitivity to high temperatures and burrs from cutting methods. Etching avoids those issues, and with process metrics and machines dedicated to aluminum etching, we can ensure high quality aluminum products with each run.
If you are ready to see how chemical etching can work for you:
To learn more about why you should celebrate photo etching during National Manufacturing Month, call us at 800-443-5218 or email your designs to us at sales@conardcorp.com and see what etching can do for you.
My boss has forgotten more about photo chemical machining than I will ever know. But, there are some things about photo etching that he thinks would make your life easier.
1. A wide selection of alloys
Photo etching works with many metals, including a wide variety alloys of iron, nickel, copper, aluminum; as well as molybdenum and silver. Here’s a more comprehensive list. If your metal of choice is not on this list, ASK ME.
2. From super thin foils to .080″ sheet
Photo chemical machining is effective for metals as thin as .0005″ (really). And is also suitable for nickel/iron *(“white metals”) up to .040″; copper alloys (“red metals”) up to .065″ and aluminum up to .080″.
3. Nadcap is not an issue
Photo etching does not alter the characteristics of the metal. There are no thermal or mechanical stresses applied during photo etching. Therefore, the process is not subject to Nadcap.
4. Tremendous size range
Photo etching can produce parts as small as .020″ diameter and our equipment can process parts up to 24″ x 60″.
5. No tool wear; no metal on metal contact
Phototools are pieces of Mylar film and are only exposed to light. Therefore, there is no “tool wear” in photo etching. What is actually cutting the metal is etchant. Therefore, SPC doesn’t apply.
6. Tiny holes, many holes: all free
Photo etching can make holes as small as .004″ (100 microns) in .002″ (50 micron) metals. The important thing is that the holes have to be larger in diameter than the metal thickness. We only charge you for the first hole. The rest of them are free. One hole or a million…it’s all the same to us.
7. Be generous with yourself; it saves money
Photo etching costs less when your dimensional tolerances are more generous. Bigger tolerances mean bigger sheets, less labor and lower costs. This white paper explains why.
8. Weird is good
Chemical etching is great at weird shapes. The cost is in the “real estate”.
9. Leave it to the pros
Conard has specialized in photo chemical machining since 1965. Let us do it for you.
To learn more about the etching process, please download our FREE Comprehensive Guide to Photo Etching.
My boss has forgotten more about photo chemical machining than I will ever know. But, there are some things about photo etching that he thinks would make your life easier.
Photo etching works with many metals, including a wide variety alloys of iron, nickel, copper, aluminum; as well as molybdenum and silver. Here’s a more comprehensive list. If your metal of choice is not on this list, ASK ME.
Photo chemical machining is effective for metals as thin as .0005″ (really). And is also suitable for nickel/iron *(“white metals”) up to .040″; copper alloys (“red metals”) up to .065″ and aluminum up to .080″.
Photo etching does not alter the characteristics of the metal. There are no thermal or mechanical stresses applied during photo etching. Therefore, the process is not subject to Nadcap.
Photo etching can produce parts as small as .020″ diameter and our equipment can process parts up to 24″ x 60″.
Phototools are pieces of Mylar film and are only exposed to light. Therefore, there is no “tool wear” in photo etching. What is actually cutting the metal is etchant. Therefore, SPC doesn’t apply.
Photo etching can make holes as small as .004″ (100 microns) in .002″ (50 micron) metals. The important thing is that the holes have to be larger in diameter than the metal thickness.
We only charge you for the first hole. The rest of them are free. One hole or a million…it’s all the same to us.
Photo etching costs less when your dimensional tolerances are more generous. Bigger tolerances mean bigger sheets, less labor and lower costs. This white paper explains why.
Chemical etching is great at weird shapes. The cost is in the “real estate”.
Conard has specialized in photo etching since 1965
To learn more about the etching process, please download our FREE Comprehensive Guide to Photo Etching.
Precision and Accuracy: Photo chemical machining allows for precise and accurate metal fabrication, enabling the creation of intricate and complex designs with dimensional tolerances of +/-15% of metal thickness and feature locations within .001”. Learn more about design for etching here.
Cost-Effectiveness: Etching is cost-effective for production runs of dozens to hundreds of thousands, depending on the parts. Compared to traditional machining. etching requires less set up time and can be more efficient in material consumption.
Versatility in Materials: Photo chemical machining is compatible with many metals, including a wide range of steel and nickel alloys, copper alloys including brass, bronze, beryllium copper, nickel silver and Monel; also, aluminum, molybdenum, and sterling silver. Here’s a non-exhaustive list of popular alloys for etching.
Complex Geometries: Etching excels at producing parts with intricate shapes and complex geometries that may be challenging or costly to achieve through other manufacturing methods.
Minimal Material Stress: The chemical etching process does not induce stress or alter the mechanical properties of the metal. Because of this, photo chemical machining is exempt from regulation by Nadcap. (However, chemical milling –depending on the application– may be subject to Nadcap checklist 7108/5.)
Fine Detail and Resolution: Photo chemical machining can achieve high levels of detail and resolution, making it suitable for applications where fine features are crucial, such as in electronics or medical devices.
Scalability: The process is readily scalable. It is efficient for both prototyping and mass production, with consistent quality maintained across different batch sizes.
Minimal Tooling Costs: Photo chemical machining does not require expensive tooling or fixtures. Digital LED exposure equipment needs only prepared DXF files to expose patterns in the photo resist.
Clean and Burr-Free Results: The chemical etching process produces clean edges without the need for secondary deburring operations. There is no cold working or thermal impact on material properties.
Experience Matters:Conard has specialized in photo chemical machining since 1965. Our workmanship and reliability are trusted by many leading customers in aerospace, defense, and wide range of major industrial manufacturers. Here are a few you might know:
