SECTION TITLE
MATERIALS • PROCESSES • FINISHES
PCE EXPLAINED A
Jochen Kern presents the design engineer’s guide to photo-chemical etching
s a precision sheet metal machining technology, photo-chemical etching (PCE) achieves exacting tolerances, is highly repeatable and in many instances is the only technology that can cost-effectively manufacture precision metal components with the accuracy necessary in demanding and often safety-critical applications. Once design engineers select PCE as
their preferred metalworking process, it is important that they fully appreciate not only its versatility, but also the specific aspects of the technology that can affect – and in many instances enhance – product design. Here, we analyse the key considerations that design engineers must appreciate to get the most from PCE, and benchmark the process against other metal machining technologies.
PCE has many attributes that can
truly stimulate innovation and ’stretch the boundaries’ with the inclusion of challenging product features, enhancements, complexity and efficiency. It is vital that design engineers fully exploit its potential, and micrometal (incorporating HP Etch and Etchform) advocates that its customers view it as a product development partner – not just a sub-contract manufacturer – early in the design stage,
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allowing OEMs to optimise the potentials that this versatile metal machining process can offer.
GENERAL TECHNOLOGY ATTRIBUTES Photo etching can be applied to a vast spectrum of metals in a variety of thicknesses, grades, tempers and sheet sizes. Each supplier is able to process different thicknesses of metal with different tolerances, and when selecting a PCE partner to work with, it is important to interrogate precisely what capabilities they have. For example, when working with micrometal’s etching group, the process can be applied to thin metal sheets
ranging from 10 microns to 2,000 microns (0.010-2mm) with a maximum sheet/ component size of up to 600 x 800mm. Metals that can be processed include include: steel and stainless steels, nickel and nickel alloys, copper and copper alloys, tin, silver, gold, molybdenum, aluminium and hard to machine metals including highly corrosive materials such as titanium and its alloys. Tolerances are a key consideration in any design and with PCE vary dependent on the material thickness, the material, and the skill and experience of the PCE supplier. Te micrometal etching group’s
process is able to produce intricate parts with tolerances as low as ±7 microns depending upon material and its thickness, this tolerance attainment being unique among all alternative metal fabrication technologies. Te company uses a special liquid resist system to obtain ultra-thin (2-8 micron) photoresist layers, enabling a higher degree of precision in the chemical etching process. It allows the group to achieve extremely small feature sizes of 25 microns, a minimum hole diameter 80%
Design engineers are increasingly turning to PCE
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