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1. The Art and Science of Photo Etching

   March 17, 2025 10:33 am Leave a Comment

   A Fascinating Non-Conventional Metal Fabricating Option

   Photo etching, also known as photochemical machining or chemical milling, is a fascinating process that lies at the intersection of science and art. It’s a technique used in various industries, from aerospace to electronics, to create intricate metal parts with remarkable precision. In this blog post, we’ll delve into the science behind photo etching, exploring the chemical processes that make this technique possible.

   The Basics of Photo Etching:

   Photo etching involves selectively removing material from a metal sheet using chemical processes.

   Imaging

   It begins with a photoresist-coated metal sheet, typically made of materials like stainless steel, copper, or aluminum. A design or pattern is then transferred onto the photoresist using a photographic process. Exposing the coated metal sheet to UV light through a photo mask hardens the exposed areas of the photoresist.

   Developing

   The unexposed areas of resist remain soluble. The unexposed resist is “developed” by spraying it with an alkaline solution between 9 and 11 pH that washes the uncured material away, leaving bare metal.. This creates a stencil-like pattern on the metal surface, protecting certain areas from chemical attack in the subsequent etching step.

   Etching

   Once the photoresist pattern is developed, the metal sheet undergoes chemical etching. Conveyorized etching systems spray the etching solution onto both side of the plates using oscillating spray bars. The speed of  the conveyors is determined by the thickness of the metal. The etchant removes material from the exposed metal surface, effectively “corroding” away the unwanted portions while leaving the protected areas untouched.

   The chemical reaction between the etchant and the metal is a critical aspect of the process. The choice of etchant, its concentration, temperature, spray pressure and other factors influence the rate and uniformity of material removal. Ferric chloride etching solution is widely used for stainless, nickel and copper alloys,  Ferric nitrate will etch silver and molybdenum. Aluminum will etch in both acids and bases.

   Consistency and Control are Critical

   Controlled etching is essential for achieving precise and consistent results in photo etching. Factors such as etchant composition, temperature, pressure, and etching time must be carefully controlled to ensure uniform material removal across the metal sheet.

   Temperature control is particularly crucial, as variations can affect the etchant’s reaction rate and the quality of the etched features. About 300 gallons of etching solution are in circulation in a double chamber etching machine. Thermal probes constantly react to changes in temperature, calling for the heaters or chilled coolant to maintain 122 +/- 3 deg F.

   In addition to spray bar pressure and conveyor speed, other sensors and probes are paying attention to the condition of the etching solution, calling for “regeneration” by adding oxidizing agents and hydrochloric acid to restore the solution’s “oxygen reduction potential.”

   Finishing the Process

   Once the desired etching  is completed, the metal sheet is “stripped” thoroughly in a caustic solution to remove the photoresist and rinsed in deionized water. After inspection of the etched parts, there may be other operations, such as: forming, plating, heat treating, etc.,  that we have a network of suppliers to provide.

   Photo etching is a sophisticated manufacturing technique that relies on precise control of chemical processes to create intricate metal parts. Understanding the science behind photo etching, from photoresist patterning to controlled etching, is essential for achieving high-quality results. By mastering these chemical processes, manufacturers can unlock the full potential of photo etching in various industries, from aerospace and electronics to medical devices and beyond.

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2. Should MEMS, wearables OEMs turn to Photo Etching to meet their needs?

   9:57 am Leave a Comment

   
   The booming market for wearables is presenting considerable opportunities for MEMS manufacturers, and photo etching can help.

   Consumers are going crazy for wearables – “smart” devices that track personal health and fitness data and present it to the wearer in a way that allows them to make better nutritional and exercise decisions. Recently, Micro Manufacturing looked at research from Gartner and found that the total market size for the wearable products category is slated to reach 91.3 million units shipped by the end of 2016, up from 68.1 million units in 2015.

   New wearables call for small size, big performance
   OEMs that get tasked with making these devices are going to have their work cut out for them. The thing with wearables is that the products are getting smaller and smaller. And don’t think for a second that smaller means less powerful – the companies that put their names on the products want their customers to know that they can get these mini-devices without sacrificing performance.

   As Micro Manufacturing wrote, these always-on, always-connected products use a considerable amount of power. This is no small feat when you consider just how small these batteries and other component parts are getting. To maximize the device’s potential, OEMs must find the most efficient combination of mechanical and electrical components that can fit all on one miniscule chip substrate. The components we’re talking about here involve MEMS accelerometers, sensors, semiconductors and other familiar parts, just brought down to the micro level.

   
   The market for wearbles is growing, and so are the opportunities for MEMS manufacturers.

   Making complex, precision component parts at scale – what Photo Etching does best
   As the Gartner report showed, we can expect the market for wearables to explode within the next two years, and it’s likely that OEMs in the MEMS space will have ample opportunity to get in on the action.

   Manufacturers in this field are already well acquainted with producing parts for the RF & Microwave and wireless industries, which gives them a head start – most of these technologies have already made their way into wearables and other products that fall under the “Internet of Things” umbrella.

   “Photo Etching is one of the most effective and efficient ways to take a complex, flat design and turn it into a finished product.”

   With the high number of units expected to ship by the end of next year, OEMs are going to be expected to produce at a breakneck pace to keep up with demand. This is where things start to get complicated: They will need to create highly functional, complex component parts designed to fit in increasingly small spaces, and they’ll need to deliver them in massive batch sizes.

   Fortunately, there’s a fabrication process that suits this need perfectly: Photo Etching is one of the most effective and efficient ways to take a complex, flat design and turn it into a finished product. In fact, as the Photo Chemical Machining Institute found, the more intricate the part, the more cost effective it is to use Photo Etching as a means of fabrication.

   One reason why Photo Etching is great for this type of work is that we can work with thin-gauge metals and hold tolerances within .001″ for sheets with a thickness of .005″ and under. Additionally, the process produces no burrs or thermal distortions in the finished product. This is absolutely key when making parts where even the slightest flaw can compromise the finished product.

   Another thing that makes Photo Etching an excellent choice, especially where big batches are concerned, is that the tooling costs are very low compared to other fabrication methods like stamping, milling and laser cutting. Phototools can be generated in a matter of hours from a customer-supplied CAD file. Most tools range in price from $185 to $350, and can be rapidly and inexpensively regenerated to accommodate revisions to parts.

   For more information about the photochemical etching process:
   Visit the Tech Library

   If you’re an OEM who is already involved, or is looking to move into the MEMS space, call us at 800-443-5218 or email us at sales@conardcorp.com and let’s get started working on your designs!

3. Sheet Size and Tolerances: Cost Drivers in Photo Etching

   9:29 am Leave a Comment

   

   Three Leading Factors

   The three biggest variables affecting the cost of photo etching are metal thickness, sheet size and tolerances. Metal thickness bears directly on the length of time it takes to etch through a given metal thickness measured in minutes per mil (.001″) of thickness. Sheet size drives the amount of labor that accumulates.

   Large or Small: All Sheets have the Same Process

   The photo etching process has seven essential steps: cutting, cleaning, laminating, printing, developing, etching and stripping. For each of these steps, a sheet of material must be handled. Each time a sheet is handled into and out of a step in the photo etching process, labor is applied. If you were loading and unloading a pizza oven, your hands wouldn’t care if it was a small pizza or a large pizza. You can easily see that loading and unloading many small sheets (pizzas) consumes more labor than handling a smaller number of large sheets.

   Tolerances Drive Sheet Size

   Let’s take a basic part: 1-inch diameter .010- inch thick stainless steel disk. (It could be a washer or even a screen because the holes just don’t matter to cost.)

   With tolerances of +/-.005″, we could run this on an 18 x 24 sheet. There would be 336 pieces on the sheet and 5000 pieces would cost $.77ea ( less metal cost.)

   At +/-.003″, we would run a 12 x 24 sheet with 210 pieces at a cost for 5000 pieces at $1.03.

   At +/-.002″, the sheet would be 12 x 12 with 100 pieces, and the price would be $1.69 each.

   If you desperately needed +/-.0015″, the sheet size would drop to 6 x 12 with 50 pieces; the yield would also likely drop below 80% and require 100% inspection. The price of such folly would be $3.57 each.

   When Perfect is the Enemy of the Good

   I get it. The 6-Sigma frame of mind wants to drive out variability in every dimension. What we have observed on a number of occasions is that designers and engineers don’t have an accessible reference to understand the cost impacts of overly restrictive tolerancing, especially in the context of particular applications.

   We are happy to provide nuanced quotes so that you can see the impact of tolerances on costs. Just let up know what you need. Quotes are always free!

   

4. 5 reasons OEMs should choose a value-added supplier for Photo Etching

   9:13 am Leave a Comment

   
   Here are five reasons why you should consider a value-added photo etching supplier for your OEM.

   It’s surprising to get inquiries from OEMs asking to buy photo etching equipment for an in-house operation. There is a widespread perception that etching machines are like any other – just plug it in and go- but this couldn’t be further from the truth.

   Setting up even a small PCM operation requires multiple pieces of capital equipment, a high level of expertise as well as a variety of chemical solutions and process metrics, adherence to strict environmental regulations and quality standards, and so on.

   With that in mind, here are five reasons why you should consider a value-added photo etching supplier for your OEM.

   Commitment and expertise
   Creating high-quality photo etched component parts comes with a steep learning curve – this is why there are fewer than 100 photo etching companies in the entire U.S. While the field is small, we’re

   “OEMs should consider the time and resources it would take to match a specialty provider’s expertise in this field.”

   very well-versed in the intricacies of the etching process such as safely and efficiently mixing, transporting and using a variety of chemical solutions and etching machines.

   Based on our research, most etching suppliers have been in the business for at least 20 years, with many of them beating the 30 year mark.

   At Conard, we’ve been in business for 49 years and our employees have been with us for an average of 12 years, and thanks to our longevity we’ve honed our process to the point where we can deliver industry-leading quality, value and service and are always looking to improve these processes.

   When looking for a photo etching solution OEMs should consider the time and resources it would take to match a specialty provider’s expertise in this field.

   Wide-ranging cost savings
   One thing about photo etching that may get overlooked is the costs associated with it. Here are just a few of the costs that photo etching produces:

   • Utility Costs: Etching requires the use of water- and energy-intensive equipment.
   • Supply costs: Etchant, developer, stripper and photoresist are significant contributors to the cost of goods. If you don’t have a steady etching operation, these costs do not amortize efficiently.
   • Regulatory costs: PCM operations must adhere to strict environmental regulations. Failure to comply can result in onerous fines.
   • Maintenance costs: Constant maintenance is needed to keep production equipment in top working condition.

   Dedicated etching companies know how to best mitigate these costs, and OEMs would benefit greatly by leaving it to the professionals.

   Efficient, turnkey service for multiple operations
   Sometimes the parts you need aren’t a one-step process. You may need additional services like welding, heat treating, metal finishing, etc. A good supplier will have these operations readily available so it can quickly and efficiently deliver finished products.

   For example, we keep our tooling and raw materials stored on-site. This is a huge advantage when it comes to both quality and time-saving. The photo tools are highly sensitive to variations in temperature and humidity. Yet even experienced chemical etching companies often store their tooling elsewhere, with sometimes significant environmental differences. Our General Manager, Arthur Long explained why this is a bad idea.

   “There’s a lot of etching companies who keep their film libraries somewhere else, which doesn’t make sense. You bring it in and it takes a long time to stabilize. It wastes a lot of time,” Long said. “You want to store your tools in the same place you use them.”

   OEMs stand to win by working with highly-integrated suppliers that can provide a multitude of services quickly because it saves both time and money.

   
   Experienced etching operations will have a strong grasp on the disposal process, constant documentation of waste removal and be able to do it while keeping costs down.

   Rigorous standards for quality
   A good value-added supplier will be able to demonstrate a commitment to the strictest standards for quality. An OEM shopping around for a supplier should look for AS9100/ISO9001, ITAR and RoHS qualifications among others. You can be sure that a company that adheres to these stringent guidelines will deliver high-quality parts.

   Compliance with strict environmental regulations
   Photochemical etching is very chemical intensive, and in every area of the country there are very strict regulations regarding the transport and disposal of chemicals. Noncompliance will bring substantial financial and legal repercussions.

   A dedicated PCM supplier will be best equipped to deal with these standards. In addition to being RoHS compliant, we understand the chemicals we work with better than anyone and we know what it takes to properly recycle or dispose of them. OEMs that used to etch in house have since shed their etching operations because regulations started getting so strict – something that persists to this day.

   Experienced suppliers will have a strong grasp on the disposal process, constant documentation of waste removal and be able to do it while keeping costs down.

   If you’re a decision maker at an OEM and are interested working with a value-added supplier for your chemical etching needs, call us at 800-443-5218 or email us at sales@conardcorp.com and lets get started on your designs.

   Download Now
   Engineering Design
   Guidelines

5. Quality Control in Photo Chemical Machining: Ensuring Accuracy and Consistency

   9:09 am Leave a Comment

   The inestimable Lily Tomlin once posed the question: ” if we ejected quality control from every factory in America, would quality just run rampant?”

   “Control” vs “Assurance”

   In the world of manufacturing, precision and consistency are paramount. This is especially true in processes like photo chemical machining (PCM), where intricate metal parts are created using chemical etching.

   Control is a function of design.  It starts with the part and its dimensions and tolerances. It continues into the careful development of a production process that can meet the specifications.

   At each step in the production process- photo etching has seven key steps-there must be specific and detailed instructions about how the step is to be performed and how the work is to be validated. A key piece of that process is the training and verification of the operator(s).

   The entire process and the means of executing it must be carefully planned, tested, and verified at each step. The part design feeds  into the process design and the work instructions and operator training. If all of these are done properly, then the probability of success should be very high.

   Assurance proves that the process succeeded.   Assurance involves a series of measures and checks designed to verify that each part meets the specified tolerances, dimensions, and other requirements. It is essential for maintaining consistency across production runs and ensuring that the final products meet the customer’s expectations.

   Getting Ahead of the Curve

   ” Quality Control,” in its traditional connotation, is designed to detect defective parts after manufacture. This “inspecting the quality in”  leads to wasted materials, rework, and potential delays in production. By implementing robust control procedures in the design of parts and processes, and couple them with process assurance steps, manufacturers can minimize these risks and deliver high-quality parts consistently.

6. Pushing the Photo Etching Envelope

   9:03 am Leave a Comment

   We have talked a great deal about photo etching “rules of thumb” and general design guidelines. And, these guidelines apply to the vast majority of the work we do. But, the rules aren’t necessarily absolute. We have been able to solve some very delicate problems for customer applications by adapting chemical etching process elements to achieve much greater precision and control.

   These adaptations are outside of standard process parameters for photo etching and required a fair amount of engineering effort and testing. We were successful in achieving very tight dimensional tolerances (+/-.0003″) and a consistent and repeatable process for scaling up production.

   In this particular case, we were fighting the inherent efficiency of our photo etching process with it’s predictable and consistent rate of material removal. The “sweet spot” for this application was mere seconds. Given our automatic system for regenerating the etching chemistry, there really is no waiting for spent etchant to buy more time. But that thought triggered a new plan.

   By changing the rules of our standard process, we were able to remove the time pressure and gain a tremendous amount of very fine control of the process which made it possible to meet the requirements of this etching application. The customer’s response was elation, as this had been a very thorny problem for them.

   And, yes, it does cost more than a standard chemical machining process, but the yield improvement for the customer more than offset the increase in the production cost of etching, as well as substantially reducing their burden of rework.

   The lot-to-lot consistency of this process may soon allow them to drop the 100% inspections to a 2.5 AQL, saving nearly $2 per part. Although cost saving was not their primary motivation, they will not mind it one bit.

   We are very pleased that we were able to find a unique and effective method to meet the customer’s requirements, and in a way that we know is controllable and repeatable day after day.

   This is one of the ways that we are willing to go beyond the conventional wisdom of industry practices to solve complex and challenging customer problems. It helps a great deal that we have a tremendous pool of knowledge, experience and talent within the company who have the insight to think differently about demanding projects. In some places, as this customer experienced, they were simply told that what they wanted/needed couldn’t be done.

   So, if you have a project that some have said couldn’t be done, give us a call (800-443-5218). Or send me an email,

   Download
   FREE Guide on
   Design Considerations
   for Photo Etching

7. Powering the Future: Photo Etching for Energy Generation and Storage

   8:58 am Leave a Comment

   Discover the revolutionary applications of photo chemical etching in power generation and storage.

   Photo Chemical Etching Process

   Photo chemical etching is a highly precise manufacturing process that involves using a combination of chemical and light-based techniques to selectively remove material from a metal sheet or plate. This process allows for the creation of intricate and complex parts with tight tolerances and high accuracy.

   After applying a UV light-sensitive photoresist material onto the metal surface, a pattern or design is then transferred onto the photoresist using a photomask or direct digital imaging. In developing, the unexposed resist is washed away, leaving bare metal exposed to the etching solution

   At etching, we inundate the metal sheet in a chemical solution that dissolves the exposed areas of the metal. The remaining photoresist acts as a protective layer, preventing the underlying metal from being etched away. Once the desired depth of etching is achieved, the remaining photoresist is removed, and the etched metal part is ready for use.

   Photo chemical etching offers several advantages over traditional machining methods. It allows for the production of complex parts with intricate geometries that would be difficult or impossible to achieve with conventional machining techniques. It also eliminates the need for expensive tooling and reduces material waste. Additionally, the etching process can be easily scaled up for mass production.

   In the power generation industry, photo chemical etching is used to create various components, such as fuel cell plates, battery componets, heat exchangers, and electrical contacts. Its ability to produce intricate parts with high precision makes it an ideal manufacturing method for these applications.

   Conquering Challenging Part Geometries with Photo Chemical Etching

   One of the major advantages of photo chemical etching is its ability to conquer challenging part geometries, especially “all-over”  designs such as partial depth channels in heat exchangers and thermal planes. Conventional machining addresses each feature serially, while etching addresses the entire surface at once. Photo chemical etching allows for the production of parts with tight tolerances and intricate features.

   The process can easily accommodate the creation of parts with irregular shapes, fine details, and small features. This makes it ideal for manufacturing components used in power generation and storage, where the efficient use of space and precise functionality are crucial.

   Whether it’s creating intricate fuel cell plates with precise channels for efficient flow of reactants, or fabricating heat exchangers with complex fin patterns for enhanced heat transfer, photo chemical etching provides a versatile solution for conquering challenging part geometries.

   By leveraging the capabilities of photo chemical etching, manufacturers in the power generation industry can overcome design limitations and create innovative solutions that maximize performance and efficiency.

   Enhancing Energy Storage with Photo Chemical Etching

   Photo chemical etching has many applications in energy storage systems. Etching high-performance battery components, such as current collectors and busbars, is among the more well-known uses of etching.

   The etching process allows for the creation of intricate electrical contact patterns on the surface of the battery components. These patterns maximize the contact area between the battery electrodes and the current collectors, resulting in improved energy transfer and reduced resistance.

   In addition to improving electrical performance, photo chemical etching can also be used to create microstructures on the surface of electrodes, enhancing their surface area. This increased surface area enables higher energy storage capacity and faster charging and discharging rates.

   Photo chemical etching of energy storage components offers the power generation industry higher efficiency, longer battery life, and improved overall system performance.

   Photo Chemical Etching Advanced Process Controls

   Digital controls allow for more tightly controlled parameters, such as temperature, pressure, speed, and etchant efficiency that contribute to achieving higher precision and tighter tolerances.

   Direct digital imaging enables manufacturers to create parts with even tighter tolerances and more precise geometries. Additionally, new materials and alloys can now be etched using specialized etchants, expanding the range of applications for photo chemical etching.

   The continuous innovation in photo chemical etching technology opens up new possibilities for the power generation industry, enabling the development of more efficient and advanced energy generation and storage systems.

   The Future of Energy Generation with Photo Chemical Etching

   As the demand for clean and renewable energy sources continues to grow, the role of photo chemical etching in energy generation becomes increasingly important.

   In the future, we can expect to see further advancements in photo chemical etching technology, enabling the manufacturing of even more efficient and cost-effective energy generation and storage systems.

   By harnessing the power of photo chemical etching, the future of energy generation looks promising, with cleaner and more efficient solutions that can meet the world’s growing energy needs.

8. Planning Ahead- Now More than Ever

   8:49 am Leave a Comment

   How long can it take?

   I have had to deliver some displeasing news to a number of customers of late. Metal lead times have gone crazy: phos bronze-40 weeks; 321 stainless 22 weeks; a variety of copper alloys are running 10-20 weeks. We used to be able to get custom rolled strip in 6-8 weeks; but now the re-rollers can’t get the feed stock. I have been begging and pleading with customers to get on the ball and get stuff ordered so we can–at least– get in the queue for metal. And, don’t think that a “rated” order is going to help you. The mills have all of the “rated” orders already. Yours is just another in a long line.

   What’s really available?

   To the extent possible, we are encouraging customers to consider–at least in the short term–using alternative alloys that are more available. Here’s the stock list from a very reputable distributor of stainless alloys. And, this company does a really good job with many copper alloys. For great selection and quick turn on small quantities, we think these guys do a great job, too.

   And, of course, you can always just ask us.

   How do we get ahead of this?

   One of the logical consequences of having to deal with such a protracted raw material supply situation is that it makes a compelling argument for establishing LTAs/blanket orders ( or whatever you might call them). This helps us help you.

   The benefits of long term programs include:

   • cost stability
   • more reliable delivery
   • lower overall cost
   • greater ability to respond to changes in demand
   • preferential position in the production queue

   When will this be over?

   It is going to take some time–likely measured in years– for the supply chain to be replenished. And, it will likely be more “rationalized” than it was before. The diversity of alloys and gauges stocked in distribution will probably decline again, as it did after the 2008 recession. So, it becomes even more important for designers, engineers and other specifiers to talk to their suppliers about what materials are really available….the rest of them simply will be “unobtainium.”

    

   Who’s next?

   Gotta run…I have to let a customer know that the .009″ C194 copper he wants is 40 weeks and $10,000 away….

9. Photo Chemical Machining: the V-8 Juice of Metal Fabricating

   8:41 am Leave a Comment

   Wish you had thought of it, right?

   Have you ever slapped yourself on the forehead and thought: darn it….I could have had that photo etched.   No, probably not.  It’s a widespread problem with photo etching. Not enough people are aware of the capabilities of the process, which dates back the 1950s and evolved from the printed circuit board industry.

   Lasers and plasma and waterjet cutting weren’t even ideas back then.

   What’s in a name?

   Part of the confusion arises from multiple nomenclatures:

   Photo etching, chemical etching and photochemical machining are all used to describe the same process.

   It’s also common for people to “mis-mean” these two processes. Chemical milling is a separate process . And, MetalPhoto doesn’t involve etching at all.

   How to tell them apart…

   The first three terms are interchangeable and describe a process of coating sheets of metal with photoresist, exposing the resist through, essentially, a stencil we call a phototool, developing the exposed resist and then etching away the unprotected metal. Chemical milling usually refers to soaking a partially masked component, such as a jet engine nacelle, in an etching solution in order to remove metal in selected areas, generally to reduce the weight of the part. MetalPhoto® is a process most often used in the nameplate industry that involves emulsion-coated aluminum that is exposed using a phototool and then fixed in a photographic developing solution and topped with a sealer. There’s no etching at all in this process.

   When people think about metal fabricating processes, photo etching isn’t typically top-of-mind. We would really like to change that. There is a wealth of information about the etching process and its capabilities throughout this website. We hope you will take some time to poke around.

   Quick things to know…

   The basic facts are:

   • Etching works with lots of alloys: stainless and carbon steels, nickel and copper alloys, aluminum, molybdenum and silver
   • thicknesses from .001″ to .080″ (in aluminum)
   • we only charge for the first hole; no matter how many, all the other holes are free
   • dimensional tolerances are +/- 15% of metal thickness
   • phototools are typically less than $500 and produced in about a day
   • there are no mechanical or thermal stresses imparted and parts are burr-free

   So what’s not to like?  That’s what I keep saying.

   No need to be afraid…

   We may be a smallish company in the suburbs of Hartford, CT, but we serve more than two dozen of Industry Week’s leading industrial manufacturers, including 4 of their top 9 aerospace/defense enterprises. Really. Some major names on the customer list…. for a long time. So, don’t be afraid. We really do know how to work with you.

   So, the next time you start to reflexively think stamping or laser or waterjet, think V-8 juice for a minute, and give us a try. Or, just try us now!

   Request a Quote

   Or call us at 800-443-5218.

10. Photo Etching: The V-8 Juice of Metal Fabricating

    7:21 am Leave a Comment

    Have you ever slapped yourself on the forehead and thought: darn it….I could have had that photo etched. No, probably not. It’s a widespread problem with photo etching. Not enough people are aware of the capabilities of the process, which dates back the 1950s and evolved from the printed circuit board industry.

    Lasers and plasma and waterjet cutting weren’t even ideas back then.

    Yet we’re still here, since 1965.

    Part of the confusion arises from multiple nomenclatures: photo etching, chemical etching, photochemical machining, chemical milling ( which is really a separate process) and metal photo (which doesn’t involve etching at all.)

    The first three terms are interchangeable and describe a process of coating sheets of metal with photoresist, exposing the resist through, essentially, a stencil we call a phototool, developing the exposed resist and then etching away the unprotected metal. Chemical milling usually refers to soaking a partially masked component, such as a jet engine nacelle, in an etching solution in order to remove metal in selected areas, generally to reduce the weight of the part. MetalPhoto^® is a process most often used in the nameplate industry that involves emulsion-coated aluminum that is exposed using a phototool and then fixed in a photographic developing solution and topped with a sealer. There’s no etching at all in this process.

    When people think about metal fabricating processes, photo etching isn’t typically top-of-mind. We would really like to change that. There is a wealth of information about the etching process and its capabilities throughout this website. We hope you will take some time to poke around.

    The basic facts are:

    • lots of alloys: stainless and carbon steels, nickel and copper alloys, aluminum, molybdenum and silver
    • thicknesses from .001″ to .080″ (in aluminum)
    • we only charge for the first hole; no matter how many, all the other holes are free
    • dimensional tolerances are +/- 15% of metal thickness
    • phototools are typically less than $300 and produced in 24 hours
    • there are no mechanical or thermal stresses imparted and parts are burr-free

    So what’s not to like?  That’s what I keep saying.

    We may be a smallish company in the suburbs of Hartford, CT, but we serve more than two dozen of Industry Week’s leading industrial manufacturers, including 4 of their top 9 aerospace/defense enterprises. Really. Some major names on the customer list…. for a long time. So, don’t be afraid. We really do know how to work with you.

    So, the next time you start to reflexively think stamping or laser or waterjet, think V-8 juice for a minute, and give us a try. Or, just try us now!

    Request a Quote

    Or call us at 800-443-5218.