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in house laser material processing
With chemical etching at our core, we can also employ our own laser cutting and laser welding capabilities in order to achieve specific results, offering unparalleled accuracy and versatility. This means that whether your micro precision part would benefit from being manufactured by chemical etching or laser – or a combination of the two – our specialist engineers can work with you to define the optimum route to manufacture.
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 our own laser material processing capabilities.
With industry-leading technological capabilities and our metallurgical knowledge, we work with customers from early in the design phase to co-develop and manufacture complex, micro precision components.
what is laser materials processing?
Laser materials processing is a family of manufacturing techniques that use a focused, high-energy laser beam to cut, weld, mark, or shape a material. In precision metal manufacturing, the most common applications are laser cutting, laser welding, laser micromachining, and laser marking. Because the laser interacts with the material without any mechanical contact, parts can be processed without the distortion, work hardening, or burrs introduced by traditional tooling.
At Tecan, laser materials processing sits alongside chemical etching as a core capability, and the two are often used together. Chemical etching produces the primary geometry of a part, with no stress and complete consistency across high volumes, while laser processing handles the secondary features, finer cuts, and joining operations that benefit from a focused beam. Choosing between the two, or combining them, is something our engineers do at the design stage with each customer, on a part-by-part basis.
The key advantages of laser materials processing for precision components include high positional accuracy down to a few microns, the ability to handle thin and delicate materials without distortion, fast turnaround thanks to digital tooling, and clean cuts that typically need little or no secondary finishing. For complex geometries that would be difficult or impossible to produce with stamping or conventional machining, laser processing often provides the most efficient route to a finished component.
the process
cutting-edge precision
Drawing upon smart process control Tecan ensures high process stability, reliability and repeatability. Advanced laser systems producing very small beam diameters can achieve machining precision in the micrometer area. Combined with the almost negligible heat input of short-pulsed lasers this enables Tecan to manufacture high-quality, high-precision components and products in 2D as well as 2.5D or even 3D applications. Over a wide range of applications this has already given rise to breakthrough innovations that feature new functionality or higher performance.
As a micro precision specialist, Tecan covers the complete product creation process, from the early design phase to series production. In co-development, Tecan can provide engineering support to arrive at an optimised, manufacturable solution to the customer’s precision product challenge. Operating in a lean and highly digitalised and automated fashion – ultimately achieving one-piece flow – Tecan can offer cost-effective first-tier supply.
With industry-leading technological capabilities and our metallurgical knowledge, we work with customers which typically involve us in the early design phase to co-develop components from the first functional prototype to a fully industrialised technological solution.
benefits of combining laser material processing with chemical etching
precision and accuracy
Chemical etching is renowned for its ability to produce intricate designs with high precision. It uses a controlled chemical reaction to remove material, ensuring smooth edges and no mechanical stress on the metal
Laser machining, on the other hand, utilises a concentrated laser beam to achieve clean and accurate cuts.
When combined, these methods can produce parts with extremely tight tolerances and complex geometries, making them ideal for mission-critical applications in e.g. electronics, aerospace, and medical devices.
design flexibility
Chemical etching allows for the creation of detailed patterns and complex designs without altering the material’s structure
Laser machining complements this by enabling precise cuts and modifications to these designs
This combination offers unparalleled flexibility in design, allowing manufacturers to create intricate components that meet specific requirements.
efficiency and speed
Chemical etching is efficient for high-volume production, as it can process multiple parts simultaneously
Laser machining is known for its ability to quickly cut through various materials at thicknesses beyond what is economical in chemical etching.
Integrating these techniques can significantly reduce production time, enhancing overall efficiency.
versatility
Chemical etching works well with various metals, including stainless steel, copper, and aluminium.
Laser machining is versatile and can handle a wide range of materials, from metals to plastics.
This combination allows manufacturers to work with diverse materials, expanding the scope of potential applications.
durability
Chemical etching produces durable parts that can withstand harsh conditions
Laser machining ensures that the cuts are precise and the parts are free from mechanical stress
Together, these methods produce components that are not only precise but also robust and long-lasting.
cost-effectiveness
Both chemical etching and laser machining are cost-effective methods. Chemical etching is particularly economical for producing large quantities of parts with consistent quality.
Laser machining, however, leverages this same affordability for more precise features when over small areas.
Combining these methods can therefore lower production costs while maintaining high standards of quality.
applications
The integration of chemical etching and laser machining is beneficial across various industries, including:
- Electronics: produce intricate components enhancing the performance and miniaturisation of electronic devices
- Aerospace: manufacture lightweight, high-strength, high-precision parts with exceptional accuracy, improving efficiency and safety
- Medical Devices: create complex, bio-inert devices leading to better patient outcomes and advanced healthcare solutions.
- Clean Energy: enhances the precision and efficiency of manufacturing components for more reliable and sustainable energy solutions.
- Defence: allows for the production of highly accurate and durable parts, improving the performance and reliability of equipment.
- Analytical Equipment: ensures superior accuracy and detail, resulting in more precise measurements and better data quality.
- Semiconductor: enables the creation of intricate and high-quality microstructures, enhancing the performance and efficiency of electronic devices.
combining technologies under a single point of contact
Combining chemical etching and laser machining 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.
Making complex parts manufacturable
Employing the right technology for each feature
Simplifying
FAQs
frequently asked questions about laser materials processing
Chemical etching uses a controlled chemical reaction to remove material from the entire workpiece simultaneously, producing parts with no mechanical stress, no burrs, and complete dimensional consistency across high volumes. Laser materials processing uses a focused beam to cut, weld, or mark one feature at a time. Etching is typically the more economical choice for complex geometries across thin sheet, while laser processing is better suited to thicker materials, joining operations, and features that fall outside what etching can deliver. Most precision parts at Tecan use a combination of the two, with each process applied to the features it handles best.
Our laser systems handle a wide range of metals, including stainless steel, copper, aluminium, nickel, and various nickel and copper alloys. Thin-gauge sheet is our specialism, with most of our work falling between roughly 0.025mm and 1.0mm in thickness, although we can process thicker materials where the application requires it. If you have a specific alloy or thickness in mind, our engineers can confirm suitability quickly.
Achievable tolerances depend on the material, thickness, and feature geometry, but for thin sheet metal we typically work to tolerances in the region of plus or minus 10 to 25 microns on critical features. For applications requiring tighter tolerances or more complex geometries, we will often combine laser processing with chemical etching to get the best of both processes. Tolerance discussions are part of our standard design-for-manufacture review at the quoting stage.
Laser cutting tends to be the right choice when the material is thicker than chemical etching can handle economically, when the part has a simple cut profile that doesn’t benefit from etching’s parallel processing, or when the feature requires a sharp internal corner that etching cannot produce. Chemical etching is typically the better choice for thin-gauge, complex geometries, parts where flatness and absence of burrs are critical, and high-volume production runs. Our engineers can advise on the optimum route for any given part during the quoting process.
We supply laser-processed components to clients in aerospace and defence, medical devices, electronics, semiconductor manufacturing, clean energy and hydrogen, industrial automation, and analytical equipment. Many of these clients use components that combine laser processing with chemical etching, particularly where the part includes both a complex etched geometry and one or more laser-cut, marked, or welded features.
Yes, and it is one of the most common ways we use laser processing at Tecan. A typical workflow is to chemically etch the primary geometry of the part, then use laser cutting or marking to add features that fall outside what etching can produce, such as identification marks, sharp internal corners, or thicker section cuts. Because both processes happen under one roof and one quality system, our customers benefit from a single point of contact and consistent quality across the full part.
The fastest route is to send us your drawing or 3D model, along with the material specification and indicative volume, via the request a quote page. One of our engineers will review the design, recommend the most suitable manufacturing route (laser, etching, or a combination), and come back with a quote. For early-stage projects where the design is not yet finalised, we are happy to have a design conversation first and help shape the part for manufacturability.
