Forming and finishing
We offer manual and semi-automatic precision forming using standard, modular and custom form tools. Where possible, bend lines can be incorporated into photo etched components, removing the need for hard form tooling.
In-house spot welding is available for formed, 3-D components which require a permanent connection, such as nickel silver screening cans.
General forming tolerances
|Metal thickness||Positional||Angular||Internal radii|
|Soft metals up to 25mm||±0.1mm||±1º||0.5 x material thickness|
|Soft metals 25mm to 100mm||±0.2mm||±2º||0.5 x material thickness|
|Soft metals 100mm >||±0.2mm||±3º||0.5 x material thickness|
|Half-hard metals up to 25mm||±0.1mm||±1º||1.0 x material thickness|
|Half-hard metals 25mm to 100mm||±0.2mm||±2º||1.0 x material thickness|
|Half-hard metals 100mm >||±0.2mm||±3º||1.0 x material thickness|
|Full-hard metals up to 25mm||±0.1mm||±1º||2.0 x material thickness|
|Full-hard metals 25mm to 100mm||±0.2mm||±2º||2.0 x material thickness|
|Full-hard metals 100mm >||±0.2mm||±3º||2.0 x material thickness|
Electropolishing and passivation
Precision Micro offers two post-etching corrosion protection processes:
Passivation purifies the component surface and forms a micro-coating of metal oxide to protect it from corrosion. This process will not change the dimensions or overall appearance of the base metal and is generally applied to extreme environment components.
Electropolishing produces a brighter, smoother surface finish, reducing surface roughness by up to 50%. By reducing micro-crevices on the metal surface, components are up to 30 times more corrosion resistant than those which are passivated, making it ideal for medical instruments.
For components which require increased surface hardness, temperature resistance, ductility or strength, we offer heat treatment by way of hardening, tempering, annealing and normalising.
Materials can be specified with a non-reflective, dull, stain, bright, mirrored or grit finish to improve component form or function.
Available post-process surface finishes include:
- Vapour blasting
- Chemical blacking
- Chromium nitride
Bonding and brazing
Precision Micro’s innovative ‘R-Bond’ technique, which uses the photo-resist protecting the material surface during chemical etching as the bonding agent, is available for components including motor laminations.
Brazing and diffusion bonding – a process in which the atoms of two metallic surfaces are interspersed using heat and pressure – is available for heat exchanger plates, cooling plates and fuel cell plates.
Wire electro discharge machining
Wire electro discharge machining (WEDM) – also known as spark erosion – uses electric current and fine wire to cut conductive materials with low residual stress to ±0.005mm accuracy.
Combining WEDM with photo etching means component profiles can be cut to tighter tolerances and achieve unique characteristics such as tapered edges. WEDM also enables the profiling of thicker, surface etched components to 3mm.
|Materials||All conductive metals|
|Material thickness||0.010mm – 6mm|
|Maximum component size||254mm x 220mm|
|Minimum feature size||0.25mm|