Chemical Etching – Precision Material Removal Through Controlled Chemistry
Chemical Etching – Informative Overview
| Feature / Parameter | Description |
|---|---|
| Process Name | Chemical Etching (Photo Chemical Machining / Chemical Milling) |
| Technology Type | Subtractive Chemical Material Removal Process |
| Working Principle | A controlled chemical reaction selectively dissolves exposed metal areas using an etchant, while masked regions remain protected. |
| Key Steps Involved | Cleaning → Photoresist Coating → Imaging/Masking → Etching → Stripping → Finishing |
| Material Compatibility | Stainless Steel, Copper, Brass, Aluminum, Nickel, Titanium, and other thin metal alloys. |
| Typical Thickness Range | 0.025 mm to 2.0 mm (varies by material and design requirements). |
| Dimensional Tolerance | Up to ±0.025 mm, ensuring high precision and consistency. |
| Surface Finish Quality | Smooth, burr-free finish with clean edges and fine detailing. |
| Advantages | No mechanical stress or deformation, burr-free, cost-effective tooling, high repeatability, suitable for complex geometries. |
| Applications | Electronic circuits, nameplates, filters, screens, shims, encoder discs, aerospace components, and decorative metal parts. |
| Tooling Type | Digital photo tooling; easy to modify and low-cost compared to mechanical dies. |
| Production Efficiency | Fast turnaround for prototypes and high-volume batches with minimal setup time. |
| Environmental Aspect | Uses controlled chemical baths; modern systems include waste treatment and recovery for eco-friendly operation. |
Chemical Etching,
also known as photo chemical machining (PCM) or chemical milling, is a highly precise, subtractive manufacturing process used to remove selected areas of metal using chemical solutions. It enables the production of complex, burr-free, and dimensionally accurate components without applying mechanical force or heat—making it ideal for intricate and delicate parts that require high precision and fine detailing.
The process begins with cleaning
the metal sheet to remove contaminants, followed by applying a photoresist coating. This coating is patterned using photolithography to define the areas that need to be etched. The exposed areas are then dissolved by an etchant—a chemical solution specifically formulated to react with the base metal. After etching, the remaining resist is stripped away, leaving a clean and accurately defined component.
Chemical etching
is compatible with a wide range of metals including stainless steel, copper, brass, aluminum, nickel, and titanium, offering consistent results with tolerances as tight as ±0.025 mm. Because the process is stress-free and does not alter the metal’s structural or mechanical properties, it is particularly suitable for thin materials and precision components.
This technology
is widely used in industries such as electronics, aerospace, automotive, medical, filtration, and decorative design, where it is used to produce items like circuit boards, encoder discs, mesh filters, nameplates, and precision shims.
Key benefits of chemical etching include no burrs or mechanical deformation, high repeatability, low tooling cost, and rapid prototyping capability. It also supports complex geometries that would be challenging or uneconomical with conventional machining methods.
In essence, Chemical Etching combines chemical science and precision engineering to deliver accurate, cost-effective, and high-quality metal components for modern manufacturing applications.
