The market for smaller, faster or smarter products is ever increasing, along with the demand for the components which enable them. This means there is a requirement for faster and more efficient metal machining that doesn’t compromise on quality. It’s for this reason that photochemical etching should become the industry’s method of choice for precision metal component prototyping.
Photochemical etching presents businesses with the opportunity to prototype components from a wide range of materials, including those typically considered difficult to machine such as stainless steel, copper, aluminium and titanium. There’s also little set up cost and components can be delivered within 24 hours of requesting a prototype.
Photochemical etching is the industry’s best kept secret, with many design engineers still deferring to “traditional” machining methods. However, industries, including automotive, aerospace, electronics and healthcare, could benefit from etching to support increased time to market demands.
Easy to define, easy to machine
Chemical etching, also referred to as chemical milling or photo etching, is a subtractive sheet metal machining process that harnesses chemical etchants to create complex and accurate precision components from almost any metal.
The process works by UV ‘printing’ a component design onto photoresist laminated sheet metal. Whatever areas of the photoresist which have not been exposed to UV light are removed, revealing the metal which is then etched away to micron accuracy.
Complex prototyping made easy
Traditional machining processes, while trusted by many, can cause various issues when producing components. For example, laser cutting, stamping and waterjet cutting can lead to metal stresses, rough cuts, burrs or heat affected zones, all of which can compromise quality and performance. With increased demand means higher production, which will cause more components to be compromised and lacking the quality required.
Conversely, photochemical etching uses chemical etchants to create complex and precision accurate components, giving businesses a more economical way to produce custom parts with the most complex designs and strict tolerances.
This is made possible by combining sheet metal with a CAD printed photoresist mask of the required components, with chemical etching providing a less intrusive and more delicate process for creating quality, intricate components.
Alongside the quality production of components, the real value of photochemical etching is found in the inexpensive and easily reworked photo-tools that ensure high accuracy and repeatability in production. This makes etching the perfect solution for providing OEMs with the critical components needed for short lead times at a great price.
Quality components without intervention
No matter the application, precision components are integral to the performance and reliability of a product or device. Such importance on production means that even the slightest imperfection can create significant disparities in the quality of the final components produced. Traditional methods can, sometimes, cause those issues.
Thermal and cutting-edge stresses are typical factors which greatly affect the quality of the components that are produced. Thermal stress results from heat generated throughout the laser cutting or wire electrical discharge machining process. Meanwhile, a cutting-edge stress resulting from stamping causes burrs and has a detrimental effect on the flatness of a blank.
Photochemical etching eliminates all potential stress as there’s no heat or physical impact during the etching process. Similarly, by removing the impact force or harsh cutting there are no burred edges in the components produced. With photochemical etching, you can eliminate all uncertainty and guarantee quality and repeatability with every component.
Reduce R&D time
During research and development, a lot of time can be spent producing, refining and testing various design iterations. This process can be simplified by photochemical etching because it eliminates many of the side effects seen with conventional machining, allowing products to be delivered to an exceptional standard in a matter of hours, instead of waiting for weeks or months. It also reduces upfront tooling costs, meaning designers can experiment without cost penalty.
While chemical etching provides manufacturers with complete simplicity, the process makes it possible for even the most complex of parts being created, opening up more possibilities for businesses and their clients.
It’s clear that photochemical etching shouldn’t be just a best kept secret, but the go to choice for machining many precise components, with reduced lead times, fewer costs, and the ability to precisely cut even the most difficult metals in larger quantities.
To find out more about photochemical etching and how it can benefit your business visit www.precisionmicro.com.
