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In this post, we look at the chemical etching process steps in more detail.
1. Material Selection
Virtually any metal can be chemically etched, in thicknesses from 0.010 mm – 1.5 mm and sheet sizes to 600 mm x 1500 mm.
Typical metals include:
- Steel and stainless steels
- Copper and its alloys
- Nickel and its alloys
- Aluminium
- Titanium
2. Pre-clean
Once a metal has been selected, it is chemically cleaned and degreased to remove debris, waxes and rolling oils, all of which could negatively affect the next step.
3. Lamination
A light-sensitive photoresist is applied to the sheet in class 10,000 clean conditions. Good adhesion is essential for highly repeatable, blemish-free components. Any issue with the bonding of the laminate could allow the etchant to come into contact with the protected areas of the metal during etching, compromising the finished parts.
4. Printing
The component design is transferred to the photo-resist by exposing the sheet to ultraviolet (UV) light through a photo-tool mask.
5. Developing
The unexposed photoresist is removed to reveal the raw material. The hardened resist will protect the part during etching.
6. Etching
Etchant chemistry (typically ferric chloride) is sprayed onto the developed sheet. The etch-time is determined by skilled technicians taking account of variables such as metal type, grade, thickness, and size which affect the end result.
Have a question? Read our 10 chemical etching FAQs
7. Stripping
The remaining photoresist is removed from the sheet, revealing the final etched components.
8. Visual and dimensional inspection
The components are visually and dimensionally inspected using state-of-the-art optical inspection equipment.
9. Finishing
Etching can be combined with other processes including:
- Plating
- Forming
- Electropolishing
- Passivation
- Heat treatment
- Brazing and diffusion bonding
- Wire EDM
Learn how chemical etching can provide greater flexibility, cost savings and time savings for your industry.
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