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Kathy Stillman

Author Archives: Kathy Stillman

  1. Supply Chain: Checklist for Photo Etching

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    6 Reasons to Consider Photo Chemical Machining for Precision Metal Parts Production
    In the fast-paced world of manufacturing, supply chain professionals must continuously evaluate the most efficient and cost-effective methods for producing precision metal parts. One technique that often goes underappreciated is photo chemical machining (PCM). PCM, also known as photochemical etching, is a subtractive manufacturing process that uses chemical etchants to remove material with high precision. This method offers significant advantages in specific scenarios, making it an ideal choice for certain applications. But when should supply chain professionals consider PCM over other manufacturing techniques such as stamping, laser cutting, or CNC machining? Here are the key factors to evaluate:

    Complex Geometries and Fine Features
    One of the strongest advantages of PCM is its ability to produce intricate, complex geometries with exceptional accuracy. Unlike traditional machining or stamping, which may struggle with fine details, PCM can create highly detailed patterns, including sharp corners, thin walls, and micro-perforations, all without the risk of mechanical stress or distortion. This makes it particularly useful for applications in electronics, aerospace, medical devices, and filtration components where high precision is required.

    Thin Metal Components
    PCM is an excellent option when working with thin metal sheets, typically ranging from 0.01mm to 1.5mm in thickness. Traditional methods like stamping or laser cutting may deform thin materials due to excessive force or heat, leading to inconsistencies in the final product. PCM, on the other hand, ensures that the structural integrity of the metal remains intact, producing burr-free and stress-free parts. This is particularly beneficial for industries requiring lightweight but strong components, such as aviation, defense, and microelectronics.

    Prototyping and Small to Medium Production Runs
    For supply chain professionals dealing with prototyping and small-to-medium batch production, PCM presents a cost-effective solution. Unlike stamping or die-cutting, which require expensive tooling and long lead times, PCM utilizes inexpensive phototools that can be quickly produced or modified. This allows for rapid design iterations and low-cost adjustments, making it an ideal choice for new product development or custom manufacturing applications.

    Material Versatility
    PCM can be used with a wide range of metals, including stainless steel, copper, brass, aluminum, titanium, and even exotic alloys like Inconel. Unlike some traditional machining methods that may struggle with harder or brittle materials, PCM etches away metal uniformly without inducing mechanical stress. This versatility makes it an attractive option for industries requiring corrosion-resistant, high-strength, or temperature-resistant materials.

    Elimination of Mechanical Stress and Heat-Affected Zones
    Mechanical processes such as stamping and laser cutting can introduce stress, warping, and heat-affected zones (HAZ) in metal components, potentially altering their mechanical properties. PCM eliminates these issues because it is a chemical process rather than a mechanical or thermal one. This results in components with superior dimensional stability and integrity, particularly important for precision applications in the medical, semiconductor, and aerospace industries.

    Cost-Effectiveness in the Right Context
    While PCM is not always the most economical choice for very high-volume production, it offers significant cost advantages in cases where expensive tooling or extensive secondary operations would otherwise be needed. Supply chain professionals should consider PCM when:

    Tooling costs for stamping or CNC machining are prohibitively high.
    Design changes are frequent and require a flexible manufacturing process.
    The component’s complexity makes other methods inefficient or costly.
    Material waste must be minimized, as PCM generates very little scrap.
    Final Thoughts
    Photo chemical machining is a valuable tool for supply chain professionals managing the production of precision metal components. Its ability to create intricate geometries, work with a variety of materials, and eliminate mechanical stress makes it an attractive alternative to conventional machining and stamping methods. While it may not be suitable for all manufacturing scenarios, PCM is an excellent choice for prototyping, small-to-medium production runs, and applications requiring ultra-precise, burr-free, and stress-free components. By understanding the strengths of PCM, supply chain professionals can make more informed decisions, optimizing cost, quality, and efficiency in their manufacturing operations.

  2. Memory Triggers for Engineers/Designers: When to Choose Photo Etching

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    8 Things to Remember About PCM

    In the world of precision metal part manufacturing, choosing the right process can make the difference between success and frustration. Engineers and designers often default to conventional methods such as CNC machining, stamping, or laser cutting. However, there are key memory triggers that should remind them to consider Photo Chemical Machining (PCM) as a superior alternative in many scenarios. PCM is a precise, cost-effective, and efficient method, particularly suited for thin metal parts with intricate features. Here are the primary memory triggers that signal when PCM is the better choice.

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  3. Essential Resources for Designers and Engineers Exploring PCM

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    For designers and engineers working with precision metal components, understanding the capabilities of photochemical machining (PCM) is crucial for leveraging its full potential. Whether you’re exploring PCM for the first time or looking for the best service providers, having the right resources at your fingertips can streamline the process. This blog post highlights key sources of information on PCM capabilities, service providers, and industry insights.

    1. Industry Associations and Standards Organizations

    Photo Chemical Machining Institute (PCMI)

    • Website: www.pcmi.org
    • Why it’s useful: PCMI is the leading industry organization dedicated to photochemical machining. It offers technical resources, research papers, training opportunities, and networking events where professionals can connect with PCM providers and experts.

    ASTM International (ASTM E150-18)

    • Website: www.astm.org
    • Why it’s useful: ASTM E150-18 outlines standard testing methods for metal etching processes, including PCM. Engineers looking for precise specifications and quality standards can refer to ASTM documents to ensure compliance in their designs.

    SAE International

    • Website: www.sae.org
    • Why it’s useful: For engineers in the aerospace and automotive sectors, SAE provides industry-specific guidance on material selection and precision metal manufacturing processes, including PCM applications.
    1. Leading Photochemical Machining Service Providers

    Many companies specialize in PCM, offering expertise in fine metal etching and component manufacturing. Below are some of the most well-known providers:

    Precision Micro

    • Website: www.precisionmicro.com
    • Why it’s useful: A Europe-based leader in PCM, Precision Micro provides technical insights on materials, design guidelines, and case studies on applications across industries like medical, aerospace, and electronics.

    Conard Corporation

    • Why it’s useful: Conard offers detailed guidelines on designing for PCM, including minimum feature sizes, tolerances, and surface finish considerations.

    Tech Etch

    • Website: www.tech-etch.com
    • Why it’s useful: Tech-Etch is a well-established U.S. PCM provider with a strong focus on precision components for medical, defense, and telecommunications applications. Their design guide is a must-read for engineers working with PCM.

    Etchform (Part of Muon Group)

    • Website: www.etchform.com
    • Why it’s useful: Based in the Netherlands, Etchform specializes in high-precision etching of metals like titanium and molybdenum, ideal for advanced engineering applications.

    Veco Precision

    • Website: www.vecoprecision.com
    • Why it’s useful: A global leader in precision metal etching, Veco offers a comprehensive knowledge base, including white papers, webinars, and case studies on PCM technology.
    1. Design Guides and Technical Papers

    For engineers designing components for PCM, having access to design guides is critical. Here are some excellent resources:

    Precision Micro’s Photochemical Etching Design Guide

    • Website: Precision Micro Design Guide
    • Why it’s useful: Covers everything from material selection to dimensional tolerances and etching depth considerations.

    Tech-Etch’s Design Guide

    • Website: Tech-Etch Design Guide
    • Why it’s useful: A detailed PDF outlining best practices, including feature size limitations and recommended tolerances.

    Conard Corporation’s Design Guide

    Springer & Elsevier Research Papers

    • Websites: SpringerLink | Elsevier
    • Why it’s useful: Engineers and researchers can find peer-reviewed studies on PCM, covering advancements in materials, etching techniques, and industrial applications.
    1. Online Communities and Forums

    For real-world discussions, troubleshooting, and networking, engineers can engage with PCM professionals through online communities:

    Eng-Tips Forums (Chemical Machining Section)

    • Website: www.eng-tips.com
    • Why it’s useful: A place for engineers to ask technical questions, share experiences, and discuss challenges related to PCM.

    Reddit – r/Manufacturing & r/Engineering

    LinkedIn Groups

    • Search Terms: “Photochemical Machining,” “Precision Metal Etching,” “Advanced Manufacturing”
    • Why it’s useful: LinkedIn hosts industry professionals, company updates, and discussions on the latest trends in PCM.
    1. Webinars, Conferences, and Trade Shows

    Attending industry events provides networking opportunities and firsthand exposure to the latest PCM advancements.

    PCMI International Conference

    • Website: PCMI Conferences
    • Why it’s useful: An excellent event for learning about new PCM technologies and networking with suppliers and engineers.

    IMTS (International Manufacturing Technology Show)

    • Website: www.imts.com
    • Why it’s useful: One of the largest manufacturing trade shows in the world, featuring exhibitors from the PCM industry.

    MD&M (Medical Design & Manufacturing Expo)

    • Website: www.mdmeast.com
    • Why it’s useful: Ideal for those designing precision components for medical applications.

    FABTECH

    • Website: www.fabtechexpo.com
    • Why it’s useful: A major event showcasing innovations in metal fabrication, including PCM technology.

    Conclusion

    For designers and engineers working with precision metal components, photochemical machining is a powerful manufacturing process. Leveraging the right resources—whether industry associations, service providers, design guides, online forums, or conferences—can help professionals stay informed and make better design decisions.

    By tapping into these resources, you can learn more about PCM’s capabilities, compare service providers, and ensure your designs take full advantage of this precise and cost-effective etching technology

     

  4. How Power Generation and Storage Systems Benefit from PCM Fabricating

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    Micrometal Bipolar plate Photochemical Machining

    Capable of Intricate Patterns and Geometries

    Photochemical machining (PCM), also known as photochemical etching, is a highly precise and versatile subtractive manufacturing process used to fabricate complex metal components. It employs photoresist and chemical etching techniques to produce intricate patterns and geometries with tight tolerances and no mechanical stress on the material. In the realm of power generation and storage systems—ranging from fuel cells to batteries—PCM offers significant performance enhancements by enabling the creation of components that are lighter, more efficient, and more durable.

    High-Precision Parts with Micro-Scale Features

    One of the most critical contributions of PCM to power generation and storage lies in its ability to manufacture high-precision metal parts with micro-scale features. For fuel cells, particularly proton exchange membrane (PEM) and solid oxide types, PCM is instrumental in producing bipolar plates. These plates are responsible for distributing gases, conducting electricity, and managing water and heat within the cell. Using PCM, manufacturers can produce bipolar plates with highly uniform and intricate flow field patterns. These precise patterns optimize gas flow and thermal distribution, directly improving the efficiency and longevity of the fuel cell.

    Moreover, PCM’s capability to create thin, lightweight components from high-performance metals such as stainless steel and nickel alloys reduces the overall weight and size of power systems without compromising structural integrity. This is especially crucial in applications like electric vehicles (EVs) and aerospace systems, where weight reduction translates to enhanced energy efficiency and extended operational range. PCM also supports the fabrication of components with sharp internal corners and fine slots, features that would be difficult or impossible to produce.

    Current Collectors and Mesh Structures for Batteries

    In battery technologies, especially in lithium-ion and emerging solid-state batteries, PCM is used to produce intricate current collectors and mesh structures. These components must provide excellent conductivity while maintaining a minimal profile to maximize the volume available for active material. PCM enables the production of ultra-thin, corrosion-resistant metal meshes with complex geometries that improve ion transport and current distribution. Enhanced current collection contributes to better charge/discharge rates, longer cycle life, and overall improved battery performance.

    Another notable advantage of PCM in these systems is its burr-free, stress-free processing. Traditional machining methods often introduce mechanical stress or thermal distortion into the components, which can compromise their mechanical and electrochemical properties. PCM, by contrast, uses no mechanical force or high heat, thus preserving the integrity of the material. This is particularly valuable in components that must maintain high conductivity and resistance to fatigue over thousands of charge-discharge or power cycles.

    Rapid Prototyping and Cost-Effective Production

    Additionally, PCM allows for rapid prototyping and cost-effective production runs, from small batches to large-scale manufacturing. This agility is vital for innovation in energy systems, where rapid iteration and customization are often needed to optimize performance for specific applications. It also supports design flexibility, allowing engineers to quickly test new architectures and geometries that might otherwise be cost-prohibitive with traditional tooling.

    Eco-Friendly

    Environmental sustainability is another area where photochemical machining adds value. The process generates minimal waste and does not rely on lubricants or cutting oils, making it more environmentally friendly. In power generation and storage, where lifecycle environmental impact is a growing concern, PCM contributes to greener manufacturing processes.

    Improved Performance and Efficiency

    In summary, photochemical machining significantly enhances the performance and efficiency of components used in fuel cells and batteries. Its ability to produce lightweight, precise, and complex metal parts with no mechanical stress enables the design of more efficient, durable, and compact energy systems. As the demand for high-performance, sustainable power generation and storage technologies grows, PCM is poised to play an increasingly pivotal role in advancing the capabilities of next-generation energy solutions.

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  5. Exploring the Capabilities of Photochemically Machining Metal Parts

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    60 years of Conard Corporation’s Photochemical Machining Expertise for Precision Metal Components

    For designers and engineers working with precision metal components, selecting the right manufacturing process is critical. Whether you’re designing intricate filtration media, thin metal parts for aerospace applications, or precision electronic components, photochemical machining (PCM) offers a versatile and high-precision alternative to traditional methods like stamping, laser cutting, or wire EDM.

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  6. Photochemical Machining vs. Other Metal Fabrication Techniques

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    Metal fabrication has come a long way, with numerous methods available for producing precision parts. Among these, photochemical machining (PCM) stands out as a unique and cost-effective technique, especially when compared to metal stamping, laser cutting, and wire electrical discharge machining (EDM). While each method has its strengths, PCM offers distinct economic advantages in specific applications. In this post, we’ll explore when and why photochemical machining is the most economical choice.

    Understanding Photochemical Machining

    Photochemical machining, also known as chemical etching, is a subtractive manufacturing process that uses chemical solutions to selectively dissolve metal, creating intricate patterns and precise components. Unlike mechanical cutting or stamping, PCM does not induce stress, burrs, or distortion in the metal. The process is ideal for working with thin metal sheets and can achieve complex geometries with high precision.

    Where PCM Has Economic Advantages

    While metal stamping, laser cutting, and wire EDM each have their place in manufacturing, photochemical machining shines in the following scenarios:

    1. Low to Medium Production Runs

    Metal stamping requires costly tooling, such as dies and presses, making it economical only for high-volume production. In contrast, PCM eliminates the need for expensive tooling, reducing upfront costs. This makes it ideal for low to medium production runs, where stamping would not be cost-effective due to amortized tooling expenses.

    2. Complex, Intricate Geometries

    Wire EDM and laser cutting can handle complex designs, but they tend to be slower and more expensive per unit compared to PCM. PCM can produce intricate patterns, including fine details, internal cutouts, and tight tolerances without secondary finishing. This makes it the preferred choice for applications requiring high precision, such as electronic components, fuel cell plates, and medical instruments.

    3. Thin Metal Components

    For thin metal parts (typically between 0.001” and 0.080” thick), PCM has a significant advantage over stamping, which can cause warping or deformation. Additionally, laser cutting and EDM can generate heat-affected zones that may alter material properties. PCM avoids these issues, providing clean, stress-free cuts that maintain material integrity.

    4. Rapid Prototyping and Design Flexibility

    Unlike stamping, which requires lengthy die-making processes, PCM allows for quick design modifications. Changes to a design require only an update to the phototool (essentially a digital mask), rather than expensive retooling. This makes PCM highly advantageous for prototyping and iterative design processes, particularly in industries such as aerospace, electronics, and R&D.

    5. High Material Utilization and Reduced Waste

    Metal stamping often results in substantial material waste, especially for intricate parts. Laser cutting and wire EDM also create material loss in the form of kerf width or vaporized metal. PCM minimizes material waste, as the chemical process selectively removes only the necessary material, leading to better material utilization and cost savings.

    6. Burr-Free and Stress-Free Processing

    Wire EDM and laser cutting often leave burrs that require secondary processing, adding time and cost. Stamping can introduce stress into the metal, affecting performance in critical applications. PCM, being a chemical process, produces burr-free parts with no induced mechanical stress, eliminating the need for additional finishing steps.

    Key Industries Benefiting from PCM

    Several industries find PCM to be the most economical option due to its unique advantages:

    • Electronics: Flexible circuits, shielding components, and connectors.

    • Medical Devices: Surgical blades, implantable components, and microfluidic devices.

    • Aerospace: Lightweight components, fuel system parts, and heat exchangers.

    • Automotive: Battery current collectors, fuel injector nozzles, and fine mesh screens.

    • Energy: Fuel cell plates and heat exchanger components.

    Conclusion

    Photochemical machining offers a cost-effective solution for producing intricate, burr-free, and stress-free components in low to medium volumes. Compared to stamping, laser cutting, and wire EDM, PCM stands out in applications that demand design flexibility, high precision, and efficient material usage. For industries needing high-performance thin metal components, PCM provides an economical and practical alternative that optimizes both cost and quality.

     

  7. Unlocking Innovation: Elevate Your Precision Metal Designs with Photo Etching

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    Pushing Design Boundaries

    For engineers and designers striving to push the boundaries of precision and complexity in metal component design, finding the right manufacturing method is crucial. Many traditional machining techniques—such as stamping, laser cutting, or wire EDM—come with limitations in terms of cost, material waste, and design flexibility. That’s where Photo Chemical Machining (PCM) comes into play.

    PCM, also known as photochemical etching, is an advanced metal fabrication process that uses light-sensitive materials and chemical reactions to etch precise patterns into metal sheets. Unlike conventional machining, PCM allows for intricate designs without mechanical stress, making it ideal for applications where accuracy, complexity, and material integrity are essential. Let’s explore why engineers and designers should consider integrating PCM into their manufacturing toolkit.

    1. Unparalleled Design Freedom and Free Complexity

    A disk, a washer and a screen are all the same thing in photo etching, all that matters to cost is the “real estate,” and the tolerance band.

    One of the most significant advantages of PCM is its ability to create complex geometries and intricate patterns that would be nearly impossible or prohibitively expensive with other methods. This process allows for:

    • Fine details and tight tolerances—PCM can achieve tolerances as low as ±10% of metal thickness, making it perfect for delicate or high-precision components.
      • There may be cost implications that can be reduced with more generous tolerances.
    • Burr-free edges—Unlike stamping or laser cutting, which can leave rough or heat-affected edges, PCM produces clean, burr-free components that require little to no finishing.
    • Micro features and high-density patterns—PCM can create features as small as 100 microns, enabling the development of fine meshes, microfluidic devices, and intricate aerospace components.
    1. Material Versatility for Diverse Applications

    Another key benefit of PCM is its ability to process a wide range of metals, including:

    • Stainless steel (commonly used in medical and aerospace industries)
    • Aluminum (lightweight and corrosion-resistant, perfect for automotive and aerospace components)
    • Copper and brass (ideal for electronics and heat exchangers)
    • High Nickel alloys including Inconel, Kovar, Alloy 42 and others (used in high-performance applications where strength and durability are paramount)

    Unlike other processes that struggle with hard-to-machine materials, PCM maintains the integrity of these metals without introducing mechanical stress, ensuring superior performance in demanding environments.

    1. Cost-Effectiveness for Prototyping and Production

    When developing prototypes or small production runs, traditional tooling and machining methods can be expensive and time-consuming. PCM eliminates the need for costly hard tooling, offering:

    • Lower initial costs—No expensive dies or molds are required, making it more affordable for low to mid-volume production.
    • Quick turnaround times—Because PCM relies on photoresist and chemical etching rather than mechanical tooling, designs can be quickly modified and produced, reducing lead times.
    • Scalability—While PCM is excellent for prototyping, it’s also highly scalable for full production runs, offering a smooth transition from design iteration to mass manufacturing.
    1. Minimal Waste and Environmental Benefits

    Sustainability is an increasing priority for engineers and designers, and PCM offers several eco-friendly advantages:

    • Reduced material waste—Unlike machining or stamping, which can produce significant scrap material, PCM removes only the necessary areas, maximizing material utilization.
    • No mechanical stress or heat distortion—Since the process doesn’t use force or extreme heat, there’s no warping or material weakening, preserving the original properties of the metal.
    • Recyclable chemicals—Many etchants used in PCM can be recovered and reused, reducing the overall environmental impact of the process.
    1. Wide Range of Applications Across Industries

    PCM is widely used across various industries that require high precision, lightweight, and intricate metal components. Some common applications include:

    • Aerospace—Lightweight, high-strength parts such as turbine components, fuel filters, and heat exchangers.
    • Medical Devices—Surgical instruments, implantable medical components, and microfluidic devices.
    • Electronics—EMI/RFI shielding, lead frames, circuit boards, and precision contacts.
    • Automotive—Fuel injection nozzles, heat exchanger plates, and fine filtration components.
    • Consumer Electronics— Cell phones, TVs, Tablets and more

     

    • Final Thoughts: The Future of Precision Metal Fabrication

    As engineers and designers continue to develop more intricate and high-performance metal parts, the demand for advanced fabrication methods like Photo Chemical Machining will only grow. Whether you’re looking to create ultra-precise aerospace components, innovative medical devices, or complex electronic circuits, PCM provides a cost-effective, high-precision, and environmentally friendly alternative to traditional machining.

    By embracing PCM, you can expand your design possibilities, reduce costs, and improve efficiency—all while maintaining the highest standards of quality. If you haven’t yet explored the potential of Photo Chemical Machining, now is the perfect time to incorporate this game-changing technology into your design and engineering process.

     

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