chemical etching or electroforming? Or both?
Whether your micro precision part would benefit from being manufactured by chemical etching or electroforming - or a combination of the two - our specialist engineers can work with you to define the optimum route to manufacture.
Electroforming and chemical etching are both precision metal fabrication processes, but they differ significantly in their methods. Electroforming is an additive process that builds up metal layers through electrodeposition, while chemical etching is a subtractive process that removes material using chemicals. Electroforming creates parts by depositing metal onto a mandrel (the mandrel can be removed to leave intricate internal geometries), whereas chemical etching selectively removes material from a substrate.
Both are ideally suited to creating micro precision features with tight tolerances. As part of the Global Forming division of IDEX Corporation, we are in a unique position whereby we can combine the two technologies in order to achieve specific precision features.
chemical etching
benefits of combining the two technologies
In order to achieve the very specific designs required, it is sometimes necessary to incorporate more than one manufacturing technology. One aspect of our integrated technologies solution is combining our core process of chemical etching with electroforming. Here we consider the benefits.
precision and complexity
Chemical etching allows for the creation of intricate, high-resolution patterns with tight tolerances.
Electroforming can then build up metal layers on these etched patterns, preserving fine details while adding structural strength.
burr- and stress-free
Chemical etching is a non-mechanical process, so it doesn’t introduce stress or burrs.
Electroforming deposits metal atom by atom, also avoiding mechanical stress—ideal for delicate or high-precision parts.
material efficiency
Minimal material waste in both processes.
Electroforming only deposits metal where needed, and etching removes material selectively
material versatility
Electroforming works with nickel, copper, gold, silver, and more.
Etching can be used on stainless steel, copper, and other alloys, depending on the chemistry.
design flexibility
Etching enables the creation of complex 2D geometries.
Electroforming adds a 3D dimension, allowing for the fabrication of microstructures, meshes, and hollow or unsupported features.
cost-effectiveness
Low cost, especially at high volume.
Chemical etching is particularly efficient for medium to high-volume production
summary
feature |
electroforming |
chemical etching |
process |
additive (metal deposition) | subtractive (material removal) |
part creation |
builds up layers on a mandrel | dissolves away unwanted material |
tolerances |
±0.001 mm | ±0.01 mm or better |
aspect ratio |
deep, narrow features | 100% material thickness |
precision |
ultra-fine geometries, high precision for thin parts | high precision, fine detail, especially for thin materials and microstructures 0.01 mm to ~1.5 mm |
material range |
generally limited to conductive materials | can work with a wider range of materials |
example applications |
micro-optical components, precision nozzles | flow control discs, heat exchanger plates, microneedles, meshes and filters |
mechanical stress /burrs |
none | none |
tooling cost |
moderate | low, especially at high volume. Efficient for medium to high-volume production |
