why chemical etching underpins modern medical precision parts

In medical devices, precision is not optional. From drug delivery to diagnostics, the smallest features often define safety, performance and reliability. Photolithography-based chemical etching is a proven way to manufacture those micro-scale metal components cleanly and consistently, without introducing stress or burrs that could compromise a device. At Tecan, we have been innovating in chemical etching since 1970 and supply leading healthcare and life science organisations worldwide.

what do we mean by medical precision parts?

Medical precision parts include microfluidic features, microneedles, fine meshes and filters, precision grids, nebuliser plates, flow discs, and electronic components such as lead frames and RFI shielding. The common thread is high precision, clean edges and repeatability at scale.

the limitations of traditional machining

Stamping, CNC and laser cutting have their place, but they can leave heat-affected zones, mechanical stress or burrs that demand secondary finishing. On thin foils and intricate patterns, those effects can become the failure point. Chemical etching removes metal without force or heat input, so parts retain their base material properties and emerge burr-free and stress-free.

how Tecan’s photochemical etching works please use the steps indicated on 

• Clean the sheet to ensure perfect resist adhesion.
• Laminate a light-sensitive photoresist in a clean room.
• Develop to reveal the areas to be etched.
• Etch from both sides for accurate profiles.
• Strip the resist to release burr-free parts.
• Inspect with metrology and visual checks to your specification.

design freedom with micro-scale accuracy

• Thickness range: 25 μm to 2 mm or better.
• Typical tolerance: ±10% of material thickness, with a minimum achievable tolerance of ±12 μm subject to design, material and sheet size.
• Feature capability: micro-scale features, including features narrower than the material thickness in many cases.

materials to suit your application

We process a wide range of bio inert /medical-relevant metals and grades including stainless steels, mild and spring steels, aluminium (including aerospace grades), nickel alloys such as Inconel, mu-metal, Invar/Kovar and alloy 42, copper and oxygen-free copper, and molybdenum. If you have a specialist alloy requirement, our team will advise on feasibility.

prototyping to production, on one site

Digital tooling lets us turn your design into parts in days, not weeks, and makes iterations fast. Once validated, the same process scales to large series with tight repeatability. Because we etch, form and plate on a single site, you can compress timelines and remove multi-supplier risk.

finishing, forming and assembly

Medical parts often need specific surface finishes or downstream forming. We offer in-house electroplating with more than 20 finishes including gold, silver, nickel variants, black nickel and platinum, plus passivation and insulation, along with precision forming and assembly.

Example: nebuliser plates

We have produced micro-precision domed nebuliser plates in volume, combining etching, forming and finishing to meet demanding flow and durability requirements at competitive cost.

built-in quality and traceability

Tecan operates an ISO 9001 quality management system with full traceability. In-house chemical analysis, metrology and automated visual inspection underpin consistent results. First Article Inspection Reports (FAIR) are available for new programmes.

how chemical etching from Tecan compares for medical parts

• Edge and surface integrity: no heat-affected zones or cutting forces, so clean apertures for microfluidics, filters and meshes.
• Complexity at fixed cost: patterns etch simultaneously, so increasing aperture count or intricacy does not drive up unit cost like hard tooling often does.
• Fast iteration: digital tooling accelerates design changes and speeds time to clinical validation or launch.
• Scalable: move from early samples to large series quickly with consistent profiles and tolerances.

where chemical etching is advancing healthcare

Typical medical and life-science applications include microfluidic plates and channels, microneedles, precision grids, meshes and filters for surgical and diagnostic devices, nebuliser and atomiser plates, flow control discs, and electronics such as lead frames and shielding for implantable or wearable systems.

Ready to talk about your next medical innovation?

Share your CAD and a brief covering material, thickness, critical features, tolerances and any finishing or formingor discuss your requirements with our NPI engineers. We will recommend the most efficient route and help you design for etching from day one.