FEATURE MATERIALS IN DESIGN & PROTOTYPING


While most design engineers trust ‘traditional’ sheet metal machining


processes, for many industries – such as automotive, aerospace, electronics and healthcare – challenges can arise during the machining of complex


precision components. Photochemical etching, however, provides the ability


to prototype from the widest range of materials, as Precision Micro explains


L


aser cutting and stamping are two of the most common ways to shape


and cut detailed design features, but while dependable, they can also create problems during the process. A solution can, however, be found with photochemical etching. This is a metal machining process which uses chemical etchants to create complex and highly accurate precision components. So what are the main reasons for


choosing photochemical etching in the production process?


1. LOW BARRIER TO ENTRY Photochemical etching offers you the chance to prototype from the widest range of materials, including those deemed difficult to work with, with little to no set up costs. It also presents a more economical and efficient way to produce custom parts with complex designs and strict tolerances. This is possible by combining sheet metal with a CAD printed photoresist mask of the required components, with the chemical etching offering a less intrusive and more delicate process for creating quality, intricate components. The value of photochemical etching is


Photochemical etching: Creating complex


component prototypes


truly found through the inexpensive and easily reworked photo-tools that ensure high accuracy and repeatability in production, perfect for providing OEMs with the critical components they need on short lead times for a great price.


2. IMPROVED CUT QUALITY Precision etched components are vital elements of many applications and even the slightest blemish can create significant disparities in the quality of the final product. Traditional processing methods such as laser cutting and stamping can cause those issues. Thermal and cutting edge stresses are


familiar factors which affect the quality of the components produced. Thermal stress results from heat generated during the metalworking process. This can not only cause metal to expand and contract but, under extreme heat, it can also alter the properties of the materials used. This is very important to be aware of in components where even the slightest imperfections can affect their quality and effectiveness. When using stamping, cutting edge


stress causes a physical stretch on the cutting edge which can have a


DEVELOPING AN ALL-COMPOSITE HELICOPTER WHEEL


Advanced composite structure specialist, Carbon ThreeSixty, is leading a new 18-month project co-funded by Innovate UK to develop a revolutionary all composite helicopter wheel. The NATEP project is being delivered in partnership with the National Composites Centre, collaborating with Leonardo, and ultimately aims to improve performance, safety and full ownership cost. The aim is to design, develop and manufacture an ultra-low mass, robust, proof-of-concept carbon fibre


reinforced plastic (CFRP) wheel for rotary wing aircraft. This will offer significantly enhanced mechanical properties at approximately half the density of metallic wheels. Compared to aluminium alloys, a CFRP wheel will be lighter, with higher performance with an extended working life. The fibrous microstructure and resin stability of advanced composites mean


that fatigue life and corrosion resistance can be much improved when optimally designed. They are also said to offer weight savings of around 30-40% over forged aluminium and improved NVH (noise, vibration and harshness) performance. Weight reductions enable airframers to deliver efficiency, range and payload


improvements and provide an option for lower power density propulsion systems, such as battery-electric. Composite wheels will also be interchangeable with existing wheels, making them suitable for retrofit applications.


Carbon ThreeSixty 34 MARCH 2021 | DESIGN SOLUTIONS www.carbonthreesixty.com


Photochemical etching eliminates potential stress as there’s no heat or physical impact on the etching process


detrimental effect on the flatness of the blank, especially when high levels of precision are required. Another common issue is burring, which is caused by heat generation of physical impact that compromises the accuracy and dimensions of the most precise engineered components. Burring is so common and widely accepted that post-machining methods such as linishing and barrelling are part of the production process to minimise this. Photochemical etching eliminates


potential stress as there’s no heat or physical impact on the etching process. Similarly, with no impact force or harsh cutting, there are no burred edges. By using photochemical etching you can eliminate the uncertainty and guarantee quality and repeatability across all your components.


3. REDUCED LEAD TIMES Uncertainty can hugely affect supply chains. In manufacturing, that instability is caused by uncertain lead times. Issues on the product line create a domino effect as this leads to increased inventory and tooling costs while delivering an inconsistent service to customers. Photochemical etching can simplify this


process as it eliminates stress and burring, allowing for products to be delivered to an exceptional standard in just a few days – rather than weeks or months. It also reduces tooling costs, as the need to correct the issues caused by traditional methods is eliminated, providing certainty right down your supply chain. In addition to this, while chemical


etching provides simplicity, it also allows even the most complex of parts to be created. So, with reduced lead times, fewer


costs and the ability to precisely cut even the most difficult metals in larger quantities, it’s time to implement alternative methods to produce components of the highest quality.


Precision Micro www.precisionmicro.com


/ DESIGNSOLUTIONS


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