Combining chemical etching and electroforming offers several benefits, particularly in the manufacturing of intricate micro precision components.

key advantages

Combining chemical etching and electroforming offers several benefits, particularly in the manufacturing of intricate micro precision components.

 

Sometimes, in order to achieve the very specific designs required, it is necessary to bring together more than one manufacturing technology. One aspect of our integrated technologies solution is combining our core process of chemical etching with electroforming:

High Precision and Complexity: Chemical etching allows for precise control over material removal, while electroforming enables accurate metal deposition. This combination allows for the creation of highly detailed and complex designs

Cost Efficiency: Both processes are highly repeatable and can be scaled up for mass production, resulting in significant cost savings compared to traditional manufacturing methods

Design Flexibility: The ability to create complex shapes and designs in a single step from a single supplier reduces production time and increases overall efficiency

Material Integrity: Chemical etching does not introduce thermal or mechanical stress into the material, preserving the integrity of the components

Versatility: This combination is suitable for various applications, including aerospace, electronics and automotive industries

chemical etching

Chemical etching, also known as photochemical machining, is a subtractive manufacturing process that uses acidic chemicals to remove material from a metal surface.

Here’s a step-by-step overview:

  1. Material Selection: Choose the metal sheet, typically steel, copper, nickel, or aluminum.
  2. Pre-cleaning: Clean and degrease the metal to remove debris and contaminants.
  3. Lamination: Apply a UV-sensitive photoresist to the sheet.
  4. Printing: Transfer the component design to the photoresist using UV light.
  5. Developing: Remove the unexposed photoresist to reveal the raw material.
  6. Etching: Spray the etchant (usually ferric chloride) onto the developed sheet to dissolve unwanted metal.
  7. Stripping: Remove the remaining photoresist to reveal the final etched components.
  8. Inspection: Visually and dimensionally inspect the components.

electroforming

Electroforming is an additive manufacturing process that uses electricity to deposit thin layers of metal onto a predefined pattern.

Here’s a step-by-step overview

  1. Cleaning: Clean and degrease the metal substrate.
  2. Coating: Apply a light-sensitive coating /photoresist to the substrate.
  3. Exposing: Expose the substrate to UV light based on a CAD pattern, creating conductive and non-conductive areas.
  4. Developing: Remove the unexposed photoresist to expose the conductive areas.
  5. Electrodeposition: Place the patterned substrate (mandrel) in an electrolytic bath and pass a direct current through it, depositing metal ions onto the conductive areas.
  6. Harvesting: Separate the electroformed part from the mandrel.
  7. Inspection: Dimensional and visual inspection

applications

Combining chemical etching with electroforming is particularly beneficial for producing intricate and precise metal components.

The integration of the two micro precision technologies allows for high accuracy, design flexibility, and cost efficiency, making it suitable for various high-tech applications.

Here are some of the industries that use the processes in combination:

  • Electronics: Used for manufacturing intricate electronic components and connectors.
  • Aerospace: Produces lightweight, high-precision parts such as sensors and shielding components.
  • Automotive: Creates complex parts like filters, screens, and EMI shielding for all vehicle types.
  • Medical: Manufactures small, intricate components, filters and mesh for medical devices and wearable sensors.
  • Defence: Produces parts for unmanned aerial vehicles (UAVs) and other advanced technologies.
  • Clean energy: manufacture high-efficiency fuel cell components, such as bipolar fuel cell plates
  • Analytical equipment: create precision microfluidic devices used in analytical equipment for accurate fluid control and analysis
  • Semiconductor: produce intricate photomasks used in the photolithography process to pattern semiconductor wafers

combining technologies under a single point of contact

Combining chemical etching and electroforming leverages the strengths of both methods, resulting in enhanced precision, efficiency, and versatility. This powerful synergy is transforming manufacturing processes, enabling the production of high-quality, intricate components across various industries. We can also leverage our in-house plating services to offset the use of nickel in electroformed parts.

Making complex parts manufacturable

Employing the right technology for each feature

Simplifying the supply chain

chemical etching

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