All posts by droganetching

Manufacturing coffee filter nets with specifications: a diameter of 3.5 inches, a thickness of 0.2mm, and a mesh hole diameter of 0.05mm. The focus is on equipment costs and suitability for large-scale production (200,000 units). The analysis will also include recommendations for suitable manufacturers and their URLs.

1. Laser Cutting

Equipment Costs:

The cost of a laser cutting machine typically ranges from $100,000 to $500,000, depending on the machine’s power, precision, and automation capabilities. For applications that require high precision, such as producing filter nets with 0.05mm mesh holes, a more advanced laser cutting machine may be necessary, bringing the cost closer to the higher end of this range.
Additional equipment (e.g., gas supply systems, cooling systems) and post-processing equipment (such as deburring and cleaning machines) may add another $10,000 to $50,000.

Production Costs:

Laser cutting is well-suited for large-scale production due to its speed, but the method can cause thermal deformation, especially with thin materials like 0.2mm stainless steel. This can affect the flatness of the material and lead to additional post-processing costs.
Maintenance costs for a high-precision laser cutter are typically around $5,000 to $10,000 per year.

Suitability:

Laser cutting works well for intricate designs and precise features. However, due to the potential thermal effects on thin materials, it may not be ideal for maintaining flatness on extremely fine mesh.
Recommended Manufacturer:
- Trumpf (laser cutting specialists with a variety of options for precision cutting)
- URL: https://www.trumpf.com/en_US/

2. CNC Machining

Equipment Costs:

High-precision CNC machines generally range from $150,000 to $600,000, depending on the machine’s capabilities and features. CNC machines require precise control systems, and specialized fixtures may be needed to handle thin materials like 0.2mm stainless steel, increasing overall costs.
Custom fixtures and tooling might add another $20,000 to $50,000.

Production Costs:

CNC machining is known for its precision, making it ideal for complex designs. However, it is a slower process compared to laser cutting, which increases production costs for large volumes like 200,000 units.
The process also requires careful handling of thin stainless steel to prevent deformation due to the clamping pressure, which could result in flatness issues.
Maintenance costs for CNC machines are typically $10,000 to $20,000 annually.

Suitability:

CNC machining is excellent for high-precision applications, especially when intricate designs are required. However, it is generally slower and more expensive compared to laser cutting, which may not be ideal for large production runs.
Recommended Manufacturer:
- Haas Automation (a leading CNC machine manufacturer offering advanced precision machining solutions)
- URL: https://www.haascnc.com/

3. Chemical Etching

Equipment Costs:

Chemical etching equipment is relatively affordable, with initial costs ranging from $50,000 to $150,000, depending on the system’s automation and capabilities. The major investments include the etching tanks, chemical handling systems, and automated control systems.
Auxiliary equipment (e.g., wash tanks, drying systems) may add an additional $10,000 to $30,000 to the overall cost.

Production Costs:

Chemical etching is ideal for large-scale production and offers excellent precision, especially for thin materials. The process involves no heat, so there is no risk of material deformation, ensuring that the flatness of the stainless steel remains intact.
Maintenance costs for chemical etching equipment are relatively low, around $3,000 to $5,000 annually, mainly for chemical replenishment and system cleaning.

Suitability:

Chemical etching is the best choice for large-volume production of filter nets with small mesh sizes like 0.05mm. It offers excellent precision, low operating costs, and does not impact material flatness, making it ideal for your needs.
Recommended Manufacturer:
- Dragon Etching (specializes in chemical etching services and equipment for precision applications)
- URL: https://www.dragonetching.com/

4. Mechanical Stamping

Equipment Costs:

Stamping presses generally cost between $100,000 to $500,000, depending on the required tonnage, precision, and automation. Custom tooling and die sets could add another $10,000 to $30,000 to the initial cost.
Die costs for custom mesh patterns and hole shapes are a significant portion of the investment.

Production Costs:

Stamping is a high-speed process, ideal for large quantities. However, for thin stainless steel (such as 0.2mm), stamping can cause the material to deform, which might affect the mesh’s flatness.
Maintenance costs for stamping equipment are lower than CNC or laser cutting, typically around $2,000 to $5,000 annually.

Suitability:

Stamping is efficient for mass production of simple designs. However, the process can struggle with maintaining precision in fine mesh applications and may lead to material deformation if the metal is not sufficiently flat.
Recommended Manufacturer:
- AIDA Engineering (a leader in precision stamping technology with a focus on high-volume production)
- URL: https://www.aida.co.jp/en/

5. Electropolishing

Equipment Costs:

Electropolishing systems are generally priced between $30,000 to $100,000, depending on the size of the system and the level of automation. The primary costs involve the electrochemical equipment and associated chemical solutions.
Auxiliary equipment like polishing tanks and heating units can add $5,000 to $20,000 to the total cost.

Production Costs:

Electropolishing is primarily a surface finishing process and is used to enhance the appearance and corrosion resistance of stainless steel. It does not affect the mesh’s geometry or hole precision but improves the surface quality.
Maintenance costs are moderate, typically around $5,000 to $10,000 per year for chemical replenishment and system maintenance.

Suitability:

Electropolishing is ideal for improving the surface quality of already-manufactured filter nets, enhancing their resistance to corrosion and giving them a smooth, shiny finish.
Recommended Manufacturer:
- MacDermid Alpha (specializes in electropolishing equipment and solutions for stainless steel finishing)
- URL: https://www.macdermidalpha.com/

Summary Table

Method	Equipment Costs (USD)	Production Costs	Maintenance Costs (Annual)	Flatness Issues	Best Suited For	Recommended Manufacturer
Laser Cutting	$100,000 – $500,000	Higher	$5,000 – $10,000	Thermal deformation	Precision cutting for complex designs	Trumpf (trumpf.com)
CNC Machining	$150,000 – $600,000	Higher	$10,000 – $20,000	Clamping-induced deformation	High precision and complex shapes	Haas Automation (haascnc.com)
Chemical Etching	$50,000 – $150,000	Low	$3,000 – $5,000	None	High-volume, fine mesh production	Dragon etching (dragonetching.com)
Mechanical Stamping	$100,000 – $500,000	Low	$2,000 – $5,000	Deformation from stamping	Large-volume production of simple designs	AIDA Engineering (aida.co.jp)
Electropolishing	$30,000 – $100,000	Low	$5,000 – $10,000	None	Surface finishing and corrosion resistance improvement	MacDermid Alpha (macdermidalpha.com)

Recommendation:

For your specific requirements—producing 200,000 coffee filter nets with 0.05mm mesh holes—chemical etching offers the most cost-effective solution. It delivers high precision, maintains material flatness, and is well-suited for large-scale production. Pairing this with electropolishing will further enhance the surface quality of the finished product.

Uncategorized

Affordable Electro Metal Etching Chemical Equipment for a Smart Upgrade from Manual Etching

02/12/2024 droganetching

In the world of metal etching, precision, consistency, and efficiency are essential. However, for small businesses and individual practitioners who rely on manual etching, the challenges of scaling production and maintaining high-quality results can be daunting. But there’s a solution: electro metal etching chemical equipment—affordable, efficient, and capable of revolutionizing your workflow.

The Limitations of Manual Etching

Manual etching is an art form that requires meticulous care and attention to detail. Whether it’s for intricate designs or industrial applications, the process can be slow, labor-intensive, and prone to human error. While it’s perfect for small, customized jobs, manual etching limits scalability. As demand increases or precision becomes more critical, the need for automation becomes more apparent.

However, the high cost of traditional automated etching machines often puts them out of reach for smaller businesses. Electro metal etching chemical equipment, on the other hand, offers a perfect middle ground—combining automation and affordability for those who can’t invest in expensive equipment but need the precision and speed of modern technology.

Why Switch to Electro Metal Etching Chemical Equipment?

Cost-Effectiveness
Traditional etching machines can easily run into the tens of thousands of dollars, making them impractical for many small enterprises. Electro metal etching chemical equipment, however, provides an affordable alternative that still delivers high-quality results. This makes it a viable option for businesses looking to scale production without stretching their budgets too far.
Speed and Efficiency
Automation significantly reduces the time required for each etching project. Unlike manual etching, which can be slow and labor-intensive, electro metal etching chemical systems allow for faster, more efficient production. This increase in productivity enables businesses to take on more projects, meet deadlines, and increase profitability.
Consistency and Precision
One of the biggest advantages of automated etching equipment is its ability to produce consistent results every time. Whether you’re etching small, intricate patterns or larger industrial designs, electro metal etching chemical systems ensure uniformity in each piece. This reduces the risk of errors and ensures that every etching is up to your quality standards.
Reduced Labor Costs
By replacing manual labor with automated processes, businesses can cut down on the number of skilled workers needed. This reduction in labor costs makes it possible to allocate resources elsewhere in your operation, allowing you to focus on growing your business rather than on labor-intensive tasks.

Contributions from Leading Experts in the Field of Metal Etching

While many people are familiar with the practical applications of etching, it’s important to recognize the innovators who helped shape the process. One such individual is Dr. Brian R. Tuttle, a prominent figure in the field of electrochemical etching. Dr. Tuttle’s work has focused on refining the chemical processes involved in metal etching, allowing for better control, more precise outcomes, and greater versatility in industrial applications.

You can read more about Dr. Tuttle’s contributions to electrochemical etching here: Dr. Brian R. Tuttle – ResearchGate Profile

Another notable figure is Professor John D. Haynes, an expert in the field of materials science and etching technology. Prof. Haynes has contributed to advancing the understanding of metal surface preparation and the chemical reactions that occur during etching. His research has been critical in developing more efficient, environmentally friendly etching techniques that minimize waste and improve results.

You can explore Prof. Haynes’s work through his published papers: Professor John D. Haynes – Google Scholar

Practical Advantages of Electro Metal Etching Chemical Equipment

Switching to electro metal etching chemical equipment offers numerous advantages. Here are some of the most practical reasons to make the change:

Lower Operating Costs: By automating the etching process, you significantly reduce the time and labor required. The result? Lower overall operating costs and better use of your resources.
Versatility: Whether you’re working with copper, aluminum, or stainless steel, electro metal etching chemical equipment can handle various materials, making it versatile for different applications.
Improved Product Quality: Consistency is key, and automated systems ensure that every etch is precise, reducing variations and errors that often occur with manual techniques.

Nameplate Etching Machine Dragon Etching Download

Conclusion: An Affordable Investment for the Future

For businesses or individuals looking to upgrade from manual etching to a more efficient and precise process, electro metal etching chemical equipment is a smart investment. It offers the precision and speed of larger, more expensive machines at a fraction of the cost. By upgrading to automated equipment, you can reduce labor costs, improve efficiency, and achieve consistent, high-quality results every time.

Whether you’re a small business owner, a hobbyist, or someone looking to streamline your etching operations, electro metal etching chemical equipment can help you work smarter, not harder.

Sure, this article only recommends simple electro metal etching chemical equipment. If you need to expand or upgrade your equipment, you can check out our electro metal etching chemical equipment page.

Wet Chemical Processing Equipment List

Links to Key Experts:

Dr. Brian R. Tuttle – ResearchGate Profile: Dr. Brian R. Tuttle
Professor John D. Haynes – Google Scholar: Professor John D. Haynes

FPCB, PCB, Pcb Cleaning Solution, PCB Etching solution

Chemical processing equipment for Huawei Mate XT flexible PCB and foldable screen

11/09/2024 droganetching

Explore the full process and equipment used for manufacturing Huawei Mate XT’s foldable screen and flexible PCBs. Learn about chemical etching, LDI exposure, developers, strippers, and cleaning machines crucial for producing high-precision flexible circuits.

To analyze the chemical etching equipment used in manufacturing the Huawei Mate XT’s folding screen and folding PCB, you can break down the process into two parts: screen etching and PCB etching.

1. Folding Screen Etching

The flexible display for foldable devices like the Huawei Mate XT likely involves etching processes for organic and inorganic materials used in OLED (Organic Light-Emitting Diode) or AMOLED displays. Here’s how etching plays a role:

Materials Involved: The folding screen is typically made up of layers of organic compounds, thin metal films, and transparent conductive oxides (such as ITO – indium tin oxide).
Etching Method: Wet chemical etching or dry etching (plasma or ion-beam) may be used to pattern the electrodes and define the screen areas. This allows precise control over layer removal for pixel definition, transparent circuits, and metal traces.
Equipment:
- Wet chemical etching machines: These machines handle materials like ITO, which need precise etching to form conductive pathways.
- Dry etching equipment: For materials where plasma etching provides better control and sharper edges.

The etching must ensure uniformity and accuracy without damaging the flexible nature of the screen.

2. Folding PCB Etching

The folding PCBs (Flexible Printed Circuit Boards, FPCBs) in foldable devices involve chemical etching to create fine conductive traces on thin copper or other conductive materials. Here’s what’s involved:

Materials Involved: Flexible substrates such as polyimide (PI) or PET (polyethylene terephthalate), with copper or other metal layers used for the conductive pathways.
Etching Process: The primary method is chemical etching for subtractive manufacturing, where unwanted copper is removed to leave behind the desired circuit pattern. This is done using acidic solutions (like ferric chloride or cupric chloride).
Equipment:
- Roll-to-roll etching machines: These are commonly used in high-volume production for flexible circuits. They are designed to handle continuous sheets of substrate material, enabling efficient large-scale production.
- Precision etching machines: These machines are capable of producing fine lines and intricate patterns required for folding PCBs, ensuring flexibility and durability without compromising electrical performance.

Additional Considerations

Masking Process: Both the screen and PCB require photoresist application and development to mask areas that should not be etched. This is commonly done with photoresist coating machines and UV exposure systems.
Cleanroom Environment: Due to the precision required, these processes take place in a cleanroom environment to avoid contamination, especially for display components.
Etching Control: Real-time monitoring and control systems are critical to ensure etch depth uniformity, particularly for thin and flexible materials.

By using a combination of chemical etching and advanced processing equipment, manufacturers can create the fine, flexible structures required for both the screen and folding PCBs in devices like the Huawei Mate XT.

HUAWEI Mate XT Hands-on & Quick Review: Huawei leads the foldable phone trend again — HUAWEI Mate XT Hands-on & Quick Review

Here’s a comprehensive list of the chemical processing equipment typically involved in the production of flexible PCBs (FPCBs), along with the corresponding steps:

1. Material Preparation

Laminators: Used to apply the copper-clad film onto the flexible substrate (e.g., polyimide or PET).

2. Photoresist Application

Coaters: Machines for applying a layer of photoresist (dry film or liquid photoresist) on the copper surface. This is critical for defining the circuit pattern during the etching process.

3. Laser Direct Imaging (LDI) Exposure

LDI Exposure Machines: These systems expose the photoresist layer to UV light in the exact circuit pattern based on CAD files. LDI ensures high precision, especially for the fine lines needed in flexible PCBs.

4. Development Process

Developers: Once the photoresist is exposed, developers are used to wash away the unexposed areas of the photoresist, leaving only the areas that will protect the copper during etching. Alkaline solutions are commonly used for this process.

5. Etching Process

Chemical Etching Machines: These remove the unmasked copper to form the circuit traces. Ferric chloride or cupric chloride is used for copper etching. For flexible PCBs, this equipment is often in a roll-to-roll configuration to handle continuous substrates efficiently.

6. Stripping Process

Strippers: After etching, the remaining photoresist (which protected the copper traces) needs to be removed. Strippers use chemical solutions like alkaline-based chemicals to strip the photoresist.

7. Cleaning and Drying

Cleaning Machines: The FPCB needs thorough cleaning to remove residues from the etching and stripping processes. Cleaning machines use deionized water or other specialized cleaning agents.
Dryers: High-precision drying equipment is used to completely dry the flexible PCBs to avoid defects caused by residual moisture.

8. Solder Mask Application (Optional)

Coaters: A solder mask can be applied to protect the copper traces except for areas where components will be soldered. This is done using spray coating or screen printing.
LDI Machines: Similar to earlier, LDI exposure machines may be used to precisely define the areas where the solder mask should be removed.

9. Post-Processing

Surface Treatment: Flexible PCBs often undergo surface treatments like electroless nickel immersion gold (ENIG) or OSP (organic solderability preservative) to enhance solderability and prevent oxidation.
Cutting/Profiling: Finally, the flexible PCBs may need to be cut into specific shapes using laser cutters or CNC routers.

10. Testing

Automated Optical Inspection (AOI): This machine scans the finished flexible PCB to check for defects like open circuits or short circuits.
Electrical Testing Equipment: To verify the electrical properties of the circuits, ensuring functionality.

Summary of Equipment:

Laminators (for applying copper-clad film)
Photoresist Coaters (dry film or liquid)
LDI Exposure Machines (for circuit pattern imaging)
Chemical developing machine (to remove unexposed photoresist)
Chemical Etching Machines (ferric or cupric chloride)
Chemical Stripper Machine (for removing remaining photoresist)
Chemical Cleaning Machines (for post-etching and stripping)
Dryers (to eliminate moisture)
Coaters and LDI for Solder Mask (optional)
Surface Treatment Equipment (for solderability)
Cutting Machines (laser or CNC for profiling)
AOI and Electrical Testing Machines (for inspection)

These steps ensure that the flexible PCB is precisely etched, cleaned, and ready for further assembly into complex devices like Huawei’s foldable Mate XT.

Etching Process

How to Choose Chemical Etching vs Metal Laser Cutting From Stainless steel

09/09/2024 droganetching

As a metal processing service company, I think you need to know the comparison between laser cutting and chemical etching. I believe our article can give you the answer.

1. Technical Principles

Laser Cutting Principle

Laser cutting uses a high-powered laser beam focused on the material’s surface to melt, burn, vaporize, or ignite the material, allowing for precise cuts. In stainless steel cutting, CO2 lasers or fiber lasers are commonly used. Fiber lasers, due to their efficiency and precision, are preferred for cutting 1mm stainless steel.

Metal laser cutting machine LS7 | BLM GROUP

Chemical Etching Principle

Chemical etching is a process that removes material through a chemical reaction. For stainless steel, ferric chloride is a commonly used etchant. The process selectively dissolves exposed areas of the metal, while areas covered by a protective mask remain unaffected, resulting in detailed patterns or designs.

Chemical Etching: A Tour Through The Process (3D Animation)

2. Chemical Etching Process

Chemical etching is a multi-step procedure that typically includes the following:

Cleaning: The metal surface is thoroughly cleaned to remove any grease, dirt, or oxides, ensuring a pristine surface for etching.
Masking: A photoresist or protective mask is applied to the metal. This mask will protect areas that are not to be etched.
Exposure and Developing: The masked metal is exposed to UV light through a photomask that contains the desired pattern. After exposure, the unexposed areas of the mask are developed and removed, revealing the metal underneath.
Etching: The exposed metal is immersed in a chemical etching solution, which dissolves the unmasked areas, creating the desired design.
Mask Removal: Once etching is complete, the protective mask is stripped away, leaving the final etched design.

This process can achieve highly detailed patterns, but it requires careful handling of chemicals and waste disposal.

3. Cost Comparison

When processing 1mm 304 stainless steel, here is an updated cost comparison covering equipment, personnel, space, utilities, and environmental factors.

Machine Costs

Chemical Etching Equipment: Costs typically range from $60,000 to $120,000, which includes the etching machine, chemical storage, and safety equipment.
Laser Cutting Equipment: Prices range from $150,000 to $350,000, depending on the laser’s power and the brand.

Personnel Requirements

Chemical Etching: Requires about 3 operators to handle mask creation, chemical handling, and waste disposal. Assuming an hourly wage of $25, with an 8-hour workday, the monthly labor cost would be around $12,000.
Laser Cutting: Only 1-2 operators are needed for machine programming and supervision. With the same wage assumption, the monthly labor cost is approximately $4,000 to $8,000.

Space Requirements

Chemical Etching: Requires about 600-1,000 square feet, including space for the machine, chemical storage, and waste management. Assuming rent at $12 per square foot, monthly space costs range from $7,200 to $12,000.
Laser Cutting: Takes up 300-500 square feet, with monthly rent costing $3,600 to $6,000, less than etching.

Utilities (Water and Electricity)

Chemical Etching: Consumes significant water and electricity. Water consumption is about 4 tons per day, at $1.50 per ton, leading to a monthly water bill of $180. Electricity, primarily for pumps and heating systems, adds another $800 per month.
Laser Cutting: Has no water consumption but uses 12-18 kWh of electricity per hour. Assuming a rate of $0.12 per kWh, with 8 hours of daily use, monthly electricity costs are about $350 to $540.

Environmental Impact & Disposal Costs

Chemical Etching: The major environmental cost is waste disposal. Handling 1.5 tons of chemical waste monthly costs $800 to $1,500, plus transportation and storage fees, bringing the total to around $2,000 to $3,000.
Laser Cutting: Laser cutting doesn’t produce chemical waste, but it does create fumes and particulates, requiring filtration. Monthly filter maintenance costs about $150 to $400, making it more environmentally friendly.

Maintenance and Operating Costs

Chemical Etching: Has higher maintenance costs due to the need for regular chemical replacement and cleaning. Monthly costs range from $1,500 to $3,000.
Laser Cutting: Maintenance is simpler, involving cleaning optics and replacing consumables like nozzles. Monthly maintenance costs are about $600 to $1,200.

4. Chemical Etching vs Metal Laser Cutting Cost Table

Cost Factor	Chemical Etching	Laser Cutting
Machine Cost	$60,000 – $120,000	$150,000 – $350,000
Personnel (monthly)	$12,000	$4,000 – $8,000
Space (monthly)	$7,200 – $12,000	$3,600 – $6,000
Utilities (monthly)	Water: $180, Electricity: $800	Electricity: $350 – $540
Waste/Environmental	$2,000 – $3,000	$150 – $400
Maintenance (monthly)	$1,500 – $3,000	$600 – $1,200

Chemical Etching vs Metal Laser Cutting Cost Table

5. Conclusion

From a numerical comparison, chemical etching offers high precision but comes with higher operational costs, especially in labor, space, utilities, and waste disposal. It is best suited for intricate designs that require fine detail but demands more complex handling for safety and environmental concerns.

On the other hand, laser cutting requires a higher initial investment, but operational costs are significantly lower due to less labor, smaller space requirements, and simpler maintenance. It’s ideal for high-volume production where efficiency and cost control are critical. Laser cutting also has less environmental impact, which is increasingly important in today’s regulatory environment.

For companies focused on precision and intricate designs, chemical etching remains a strong choice. However, for high-efficiency, large-scale production, laser cutting is the better long-term investment.

Uncategorized

Why Chemical Etching is the Go-To Process for Precision Metal Parts

30/08/2024 droganetching

Chemical etching is a powerful and cost-effective method for creating detailed and precise metal parts, widely used in various industries. Whether it’s for common metals like copper, iron, aluminum, stainless steel, titanium, or for PCB manufacturing, chemical etching offers distinct advantages over alternative methods like laser cutting, CNC grinding, and CNC turning. In this article, we’ll explore the benefits of chemical etching, particularly focusing on its cost efficiency and versatility, and discuss the crucial role of chemical etching machines.

FPC connector with camera of a smartphone.

Precision and Detail in Everyday Products

Chemical etching shines when it comes to producing fine details in metals, making it ideal for a wide range of applications from everyday products to high-tech components.

Stainless Steel Filters: Stainless steel is favored for its durability and corrosion resistance, making it a popular choice for filters in various applications. Chemical etching allows for the creation of precise openings in these filters without compromising the strength of the material, ensuring high performance and longevity.
Copper Nameplates: Copper is widely used for nameplates and signage due to its aesthetic appeal and durability. The precision of chemical etching ensures that even the most intricate designs are accurately reproduced, offering a superior finish compared to other methods.
Titanium and Aluminum Precision Parts: For industries like aerospace and medical devices, where precision is paramount, chemical etching is the preferred method for creating complex parts from titanium and aluminum. These metals are difficult to machine using traditional methods, but chemical etching can achieve the desired accuracy without introducing stress or altering the material’s properties.

PCB Manufacturing: The Backbone of Modern Electronics

Printed Circuit Boards (PCBs) are critical components in all electronic devices, and chemical etching is a key process in their production. By precisely removing unwanted copper, chemical etching creates the intricate circuit patterns necessary for PCB functionality. While laser cutting and CNC machining are alternatives, they often fall short in terms of cost efficiency and the ability to produce highly detailed designs on a large scale.

Why Chemical Etching Outperforms Laser Cutting and CNC Machining

When it comes to manufacturing precision parts, chemical etching offers several advantages over laser cutting and CNC machining:

Superior Precision: Chemical etching allows for the creation of extremely fine details, which can be challenging to achieve with laser cutting or CNC machining. This is particularly important in industries where precision is critical, such as electronics and medical devices.
Material Integrity: Unlike laser cutting, which can introduce heat-affected zones, or CNC machining, which can cause stress and deformation, chemical etching is a non-contact process. This ensures that the material’s original properties are preserved, resulting in a higher quality end product.
Cost Efficiency: Chemical etching is often more economical than laser cutting or CNC machining, especially for high-volume production. The lower setup costs and ability to scale the process make it an attractive option for both large and small-scale projects.
Versatility: From thin foils to thicker sheets, chemical etching can handle a wide range of materials and thicknesses, making it suitable for diverse applications across various industries.

The Importance of Chemical Etching Machines

Central to the chemical etching process are specialized machines designed to handle the precise and controlled removal of material. These machines ensure consistency, accuracy, and efficiency, making them indispensable in the production of high-quality etched parts. Whether for PCBs, filters, or intricate metal components, chemical etching machines play a crucial role in modern manufacturing.

Conclusion

Chemical etching is the ideal solution for producing detailed, precise, and cost-effective metal parts. Whether working with copper, iron, aluminum, stainless steel, titanium, or PCBs, chemical etching offers unmatched advantages over laser cutting and CNC machining. As industries continue to demand higher precision and efficiency, chemical etching and the machines that enable it will remain at the forefront of manufacturing innovation.

Etching Process

Stainless Steel Electrochemical Etching Equipment Cost and process

05/06/2024 droganetching

Electrochemical etching of stainless steel involves a precise and controlled process to achieve high-quality results. Below is an overview of the required equipment, estimated costs, and their specific purposes. The table also includes manufacturer information for reference.

Equipment Overview and Estimated Prices

Equipment Name	Estimated Price	Purpose
Stainless steel electro Cleaning line	$4500/m	Cleans stainless steel using specific water quality standards.
Manufacturer: DragonEtching	dragonetching.com
Stainless steel electro Painting and drying line	$4500/m	Applies and dries paint with precise temperature control.
Manufacturer: DragonEtching	dragonetching.com
Exposure line	$18,000-$3,0000	Uses LED or LDI for high-precision exposure.
Manufacturer: DragonEtching	dragonetching.com
Developing line	$4500/m	Develops the exposed stainless steel accurately.
Manufacturer: DragonEtching	dragonetching.com
Stainless steel electrochemical etching line	$4500/m	Performs the main etching process using copper chloride etchant.
Manufacturer: DragonEtching	dragonetching.com
Stainless steel electro Stripping line	/	Strips away unwanted material post-etching.
Manufacturer: DragonEtching	dragonetching.com

Equipment Overview and Estimated Prices

Detailed Steps of Stainless Steel Electrochemical Etching

Stainless Steel Electro Cleaning Line

Process: Utilizes high-quality water to remove contaminants from stainless steel.
Water Quality Recommendation: Use deionized water to prevent impurities.

Stainless Steel Electro Painting and Drying Line

Temperature Control: Precise control is crucial for uniform paint application.
Process Flow: Stainless steel is painted, then dried at controlled temperatures to ensure adhesion.

Exposure Line

LED Exposure: Suitable for less complex patterns; works by exposing photoresist-coated stainless steel to UV light.
LDI (Laser Direct Imaging): Ideal for high-precision patterns; uses laser beams for direct imaging.
Work Flow:
- LED Exposure: Place the photoresist-coated steel under an LED light source.
- LDI Exposure: Use laser beams to expose the steel, adjusting parameters for pattern complexity.

Developing Line

Post-Exposure: Develops the image after exposure by removing unexposed photoresist.
Necessity: Developing reveals the pattern created during the exposure phase.

Stainless Steel Electrochemical Etching Line

Process: Involves immersing the developed stainless steel into a copper chloride solution.
Parameters:
- Temperature: Maintain between 40-50°C.
- Etchant Concentration: Typically 15-20% copper chloride.
- Experience Tips: Regularly monitor etchant strength and temperature for consistent results.

Stainless Steel Electro Stripping Line

Details: Strips away residual photoresist and other unwanted materials post-etching.
Procedure: Uses chemical baths or mechanical methods for cleaning.

Material and Etching Data Table

Stainless Steel Series	Etching Temperature (°C)	Etchant Concentration (%)	Estimated Etching Depth (µm)	Etching Quality
304	45	18	50	High
316	48	20	55	Very High
430	42	17	45	Medium
201	44	19	50	High

Material and Etching Data Table

This detailed overview covers the key aspects and equipment necessary for stainless steel electrochemical etching. Following these guidelines ensures efficient and high-quality etching results. For further information and specific product details, please visit DragonEtching.

Etching Process

Comprehensive Guide to Common Chemical Etchants and Their Applications

10/10/2023 droganetching

Chemical etching is a versatile and precise manufacturing process used in various industries, such as electronics, aerospace, and automotive. It involves selectively removing material from a substrate using chemical solutions, or etchants, to create intricate and accurate designs. In this article, we will explore several commonly used etchants, their applications, and provide a step-by-step guide for setting the temperature, concentration, and other parameters when injecting an etchant into an etching machine.

Dragone Etching PCB sheet etching equipment

Commonly Used Etchants

1. Ferric Chloride (FeCl3)

Applications:

Printed Circuit Boards (PCBs): Ferric chloride is widely used to etch copper traces on PCBs, creating the desired circuit patterns.
Metal Craftsmanship: Artists and metalworkers use ferric chloride to etch intricate designs onto metal surfaces.

Setting Parameters:

Temperature: Typically, the operating temperature for ferric chloride etching ranges from 35°C to 45°C (95°F to 113°F).
Concentration: A common concentration is around 40-45% ferric chloride in water. Ensure a consistent mix for optimal results.
Etching Time: Etching time can vary depending on the depth and complexity of the design but is typically in the range of 5-30 minutes.
Agitation: Adequate agitation ensures even etching and prevents the buildup of byproducts. Use an agitating mechanism within the etching machine.

2. Nitric Acid (HNO3)

Applications:

Stainless Steel: Nitric acid is used to etch stainless steel, making it useful in the manufacturing of medical instruments and aerospace components.
Integrated Circuits (ICs): In semiconductor fabrication, nitric acid is employed to etch silicon wafers, creating microelectronic structures.

Setting Parameters:

Temperature: Nitric acid etching is typically performed at lower temperatures, around 20°C to 30°C (68°F to 86°F).
Concentration: Common concentrations range from 10-70% nitric acid, depending on the material and desired etching rate.
Etching Time: Etching times can be as short as a few seconds for silicon wafers to several minutes for stainless steel.
Safety: Nitric acid is highly corrosive and should be handled with extreme care. Always use appropriate safety equipment and a well-ventilated workspace.

3. Sodium Hydroxide (NaOH)

Applications:

Silicon Dioxide (SiO2): Sodium hydroxide is used in the semiconductor industry to selectively etch silicon dioxide, allowing for the creation of microstructures.
Glass Etching: Artists and glassmakers use sodium hydroxide for glass etching to create decorative patterns.

Setting Parameters:

Temperature: Typically, sodium hydroxide etching is performed at elevated temperatures, ranging from 80°C to 90°C (176°F to 194°F).
Concentration: Concentrations vary but are often in the range of 5-20% sodium hydroxide.
Etching Time: Etching times can vary from a few minutes to several hours, depending on the desired depth and precision.

Setting Parameters in an Etching Machine

To ensure the successful operation of an etching machine, it is crucial to set the parameters correctly. Let’s use the example of etching a copper PCB with ferric chloride:

Temperature: Check the machine’s temperature control settings and set it to the desired range of 35°C to 45°C for ferric chloride etching.
Concentration: Prepare the etchant solution by measuring the correct amount of ferric chloride and mixing it with water to achieve the desired concentration (e.g., 40-45%). Use a calibrated measurement system to ensure accuracy.
Etching Time: Determine the appropriate etching time based on the complexity of your design. Start with a shorter time and gradually increase if needed. Typically, a 10-15 minute initial test run is a good starting point.
Agitation: Ensure that the etching machine has an agitation system in place to keep the etchant solution well-mixed during the process. Proper agitation prevents uneven etching.
Safety: Always follow safety protocols when working with chemicals. Wear appropriate personal protective equipment (PPE), such as gloves, goggles, and lab coats. Ensure that the workspace is well-ventilated and equipped with safety showers and eyewash stations.
Waste Disposal: Dispose of the used etchant solution properly in accordance with local regulations. Many etchants are hazardous waste and must be treated accordingly.

In conclusion, chemical etching is a precise and versatile manufacturing process used in various industries. Understanding the properties and applications of common etchants, as well as properly setting parameters in an etching machine, is essential for achieving high-quality results while ensuring safety and environmental compliance. Whether you’re creating intricate PCBs or crafting artistic designs on metal and glass, chemical etching offers a powerful tool for precise material removal.

Etching Process

chemical milling service specialists

27/09/2023 droganetching

what is chemical milling

Chemical milling, also known as chemical machining or chem-milling, is a manufacturing process used to selectively remove material from the surface of a workpiece using chemical reactions. This process is typically used to shape and finish metal parts and is particularly useful for producing complex and intricate shapes that are difficult or costly to achieve using traditional mechanical machining methods like milling, turning, or grinding.

Photo Chemical Machining Process — **Learn about the entire chemical milling process in this video**

Here’s how chemical milling generally works:

Masking: A protective mask or resist material is applied to the surface of the workpiece. This mask is typically made of materials that are resistant to the chemical etchant used in the process. The mask is precisely designed to expose only the areas of the workpiece that need to be chemically milled, leaving the rest of the surface protected.
Etching: The workpiece, with the mask in place, is immersed in a chemical etchant bath. The etchant is a corrosive solution that reacts with the exposed metal surfaces but does not affect the masked areas. The etchant removes material from the exposed areas by dissolving it through chemical reactions.
Rinse and Finish: After a predetermined amount of time, the workpiece is removed from the etchant bath and thoroughly rinsed to stop the chemical reaction. The mask is then removed, revealing the finished part. Additional finishing processes such as cleaning, deburring, or surface treatment may be necessary to achieve the desired final product.

Chemical milling offers several advantages, including the ability to produce parts with high precision, intricate geometries, and fine details. It is often used in aerospace and automotive industries to manufacture components like aircraft engine blades, turbine disks, and intricate parts for fuel systems.

how chemical milling works

Chemical milling, also known as chemical machining or chem-milling, is a subtractive manufacturing process used to selectively remove material from the surface of a workpiece through chemical reactions. The process typically involves the following steps:

Masking: A protective mask or resist material is applied to the surface of the workpiece. This mask is designed to cover and protect the areas of the workpiece where material should not be removed during the chemical milling process. The mask is often made of materials that are resistant to the chemical etchant used in the process.
Exposure: The masked workpiece is exposed to a chemical etchant. The etchant is a corrosive solution or chemical mixture that reacts with and dissolves the exposed metal surfaces of the workpiece. The specific etchant used depends on the material being processed and the desired rate of material removal.
Etching: As the workpiece is immersed in the etchant, the chemical reactions between the etchant and the exposed metal surfaces result in the removal of material. The etching process selectively removes material from the exposed areas while leaving the masked areas unaffected. The rate of material removal can be controlled by factors such as the concentration of the etchant, the temperature of the etchant bath, and the immersion time.
Rinse and Neutralization: After a predetermined amount of time or when the desired depth of material removal is achieved, the workpiece is removed from the etchant bath. It is then thoroughly rinsed to stop the chemical reaction. Rinsing helps remove any residual etchant and prevent further material removal. In some cases, a neutralization step may be required to neutralize any remaining acidic or alkaline residues.
Mask Removal: The protective mask or resist material is removed from the workpiece, revealing the final part with the desired shape and features.
Post-processing: Depending on the application and the final part requirements, additional post-processing steps such as cleaning, deburring, and surface finishing may be performed to achieve the desired surface quality and tolerances.

Chemical Milling Equipment

The equipment used in the production of high-precision metals and the details of how each piece of equipment works in the production of high-precision metals. Click to learn more.

Dry Film Precision Metal Chemical Milling Process

Wet Film Precision Metal Chemical Milling Process

The 2 most common chemical milling methods on the market and how chemical milling works

Metals capable of being chemically milled

Etching Process

How acid etching machines acid etch metal parts

26/09/2023 droganetching

Acid etching, also known as photo etching, chemical etching or chemical milling, is a sheet metalworking technology which uses acid etchants to machine complex, highly accurate precision metal components.

Acid etching machines are used to remove material from metal parts using acid. The process involves the following steps:

Preparation: The metal part is cleaned thoroughly to remove any dirt, grease, or contaminants from the surface. This is important to ensure proper adhesion of the acid and uniform results.
Masking: Areas that should be protected from the acid are covered using a mask or a resist material. This could be done by applying a special adhesive film or using a resist pen to draw the desired pattern on the part.
Acid application: The prepared metal part is then placed in the acid etching machine. The machine consists of a tank filled with a suitable acid solution such as ferric chloride or hydrochloric acid. The part is submerged in the acid solution, and the time and temperature are controlled depending on the desired depth and speed of etching.
Etching process: The acid dissolves the exposed metal surface, creating a recessed pattern or design. The depth and quality of the etch can be controlled by adjusting the time, temperature, and concentration of the acid solution.
Rinsing and neutralizing: Once the desired etching is achieved, the metal part is removed from the acid solution and thoroughly rinsed with water to remove any residual acid. It is then neutralized using a neutralizing agent to stop the etching process and prevent further reaction with the metal.
Finishing: After the etching process, the resist material is removed, and the metal part is cleaned, dried, and polished if necessary. This reveals the etched pattern or design on the metal surface.

It is important to follow safety procedures and use appropriate protective equipment when working with acid

What does owning an acid etching machine do?

Owning an acid etching machine allows you to perform acid etching processes on metal parts at your own facility. This offers several benefits:

Customization: With an acid etching machine, you have the freedom to customize metal parts according to your specific requirements. You can etch intricate designs, logos, serial numbers, or any desired patterns onto the metal surface. This allows for personalization and branding opportunities.
Prototyping and product development: Acid etching machines enable you to quickly and efficiently create prototypes or test different designs on metal parts. This helps in the product development process by allowing you to evaluate aesthetics, functionality, and fit before committing to large-scale production.
Production control: Owning an acid etching machine gives you control over the production process. You can etch metal parts in-house, ensuring quality control, shorter lead times, and reduced dependency on external suppliers. This can be particularly useful for businesses that require custom or small-batch production.
Cost savings: By owning an acid etching machine, you can eliminate the need for outsourcing etching services, which can be costly and time-consuming. In the long run, this can lead to cost savings and improved efficiency.
Versatility: Acid etching machines can be used on a wide range of metals, including stainless steel, aluminum, brass, copper, and more. This versatility allows you to work with different materials and expand your applications.

However, it is important to note that owning an acid etching machine also requires proper knowledge, training, and adherence to safety guidelines to ensure the safe handling and disposal of acids involved in the process.

What metals can an acid etcher etch?

Stainless steel: Acid etching can be used to create intricate designs, patterns, logos, or text on stainless steel surfaces, commonly used in the fabrication of kitchen appliances, automotive parts, and architecture.
Aluminum: Acid etching can be applied to aluminum surfaces to etch designs, text, or even photographs. It is commonly used in industries such as aerospace, signage, and decorative applications.
Brass: Brass can be etched using acid to create decorative patterns, logos, or designs. Acid etching on brass is often used in jewelry, nameplates, or decorative items.
Copper: Acid etching can be used on copper surfaces to create artistic designs, engravings, or patterns. It is commonly employed in the production of artworks, sculptures, and electrical components.
Nickel: Acid etching can be employed on nickel surfaces for various purposes, such as decorative elements, prototypes, or to create specific surface textures.
Zinc: Acid etching can be used on zinc surfaces to create intricate designs, textures, or patterns. It is often employed in architectural applications and the production of decorative items.

See all the metals our acid etchers can etch!

What do I need to know about acid-etched metal design?

Assumptions Matter: Before delving into the design criteria, it’s crucial to set the right assumptions. For instance, in the case of wet etching, we assume a specific thickness. For the purpose of this discussion, let’s consider a thickness ranging from 0.1mm.
Etching design formulas versus material thickness: Assuming a material thickness of 0.1mm, one of the first design criteria to consider is the hole diameter. To ensure proper etching, it’s often recommended to make the hole slightly larger than the material thickness. In this case, 1.2 times the material thickness would be 0.1mm * 1.2 = 0.12mm. Therefore, if the material thickness is 0.1mm, the hole should be designed to have a diameter of at least 0.12mm.
Material Choice: The choice of material plays a significant role in wet etching. Different materials react differently to etchants. Engineers must select materials that are compatible with the chosen etchant to ensure a successful process.
Hole Size Matters: The size of the holes created during wet etching is a critical design criterion. Smaller holes may lead to incomplete material removal, while larger holes may compromise structural integrity. Typically, materials with a thickness of 100μm or less can accommodate holes with a diameter of 0.12mm or more. Larger holes often result in more aesthetically pleasing and structurally sound outcomes.
Alignment and Precision: Achieving precise alignment of the etched features is vital. Design drawings should incorporate alignment markers or registration features to ensure accurate positioning during the etching process. This is particularly crucial when dealing with multilayer structures or when specific patterns must be aligned with pre-existing features.
Minimum Feature Size: It’s advisable to establish a minimum feature size for your design drawings. For instance, it’s generally recommended that no marked details be smaller than 0.1mm. This corresponds to 100μm. Maintaining a minimum feature size helps ensure that the etching process can accurately replicate the desired patterns and structures without the risk of incomplete or distorted etching.
Quality Control and Inspection: Design criteria should include provisions for quality control and inspection during and after the wet etching process. This involves specifying methods and tools for verifying that the final product meets the intended design specifications. Inspection processes may include optical microscopy, surface profilometry, or other measurement techniques to validate critical dimensions and surface finish.

Customize Your Acid Etcher from Dragon Etching

Etching Process

Wet Film Precision Metal Etching Process and Machine

25/09/2023 droganetching

Wet film etching is another key technique in the precision metal etching process, offering an alternative approach to achieving fine patterns and features on thin metal substrates.

1. Substrate Preparation:

Just like in dry film etching, the process begins with a clean metal substrate. The substrate is typically cleaned to remove any contaminants, ensuring proper adhesion of the photoresist layer.

2. Application of Photoresist:

Instead of dry film resist, wet film etching utilizes a liquid photoresist. The photoresist is applied to the metal substrate by various methods such as spin coating, dip coating, or spray coating. It forms a thin, uniform layer over the entire surface.

3. Soft Baking:

After the photoresist is applied, it undergoes a soft baking process. This step involves heating the substrate to remove solvent and to ensure the photoresist adheres well to the metal surface.

4. Exposure to UV Light:

A photomask or phototool is used to project a specific pattern onto the photoresist-coated substrate. The exposed areas of the photoresist become chemically altered and become either more or less soluble depending on the type of photoresist used.

5. Development:

The substrate is then immersed in a developer solution. The developer removes the soluble regions of the photoresist, revealing the underlying metal surface in a pattern that corresponds to the exposed areas of the photoresist.

6. Etching:

The substrate, with the developed photoresist pattern, is immersed in an etching solution, which chemically removes the exposed metal areas. The etching solution can be an acid or alkaline solution depending on the specific metal being etched. Similar to dry film etching, the etchant selectively dissolves the metal while leaving the protected areas covered by the photoresist untouched.

7. Rinsing and Inspection:

After etching, the substrate is thoroughly rinsed to remove any remaining etchant and residual photoresist. The etched features are inspected for accuracy and quality at this stage.

8. Stripping of Photoresist:

The photoresist is typically removed after etching. This can be done using a solvent that dissolves the photoresist without affecting the etched metal features.

9. Additional Processing (Optional):

Depending on the specific application, additional processes such as passivation, plating, or other post-etch treatments may be applied to the metal substrate to enhance its properties or protect it from environmental factors.

10. Final Inspection and Quality Control: – The finished metal component undergoes a final inspection to ensure that the etched features meet the required specifications and quality standards. This may involve measurements, visual inspections, and other quality control procedures.

Wet film etching offers many of the same advantages as dry film etching, including high precision, customization, and compatibility with various metal substrates. However, it has its own set of considerations and requirements, such as the need for liquid photoresists and precise control of the coating and soft baking processes. Wet film etching is commonly used in industries that require intricate metal components and where the flexibility of using liquid photoresists is beneficial.

Wet film etching, as an alternative to dry film etching, possesses several distinctive features and advantages, making it suitable for specific applications.

Homogeneous Coating Thickness:
- Wet film etching allows for the deposition of a highly uniform and consistent photoresist layer on the metal substrate. This results in even etching across the entire surface, reducing variations and defects in the final product.
Excellent Adhesion:
- Liquid photoresists can offer strong adhesion to metal substrates, ensuring that the resist adheres firmly during the etching process. This helps maintain the integrity of the mask pattern and prevents delamination.
Variety of Photoresists:
- Wet film etching can use a wide range of photoresist types, including positive and negative photoresists, each with its own characteristics. This versatility allows for the selection of the most suitable resist for the specific application.
Versatile Substrate Compatibility:
- Wet film etching is compatible with various metals and alloys, similar to dry film etching. This versatility enables manufacturers to choose the material that best suits their requirements.
Multi-Layer Etching:
- In some cases, wet film etching can be used for multi-layer etching processes where different metals or materials are etched sequentially, allowing for complex component manufacturing.
High Aspect Ratio Etching:
- Wet film etching can achieve high aspect ratio features, meaning it is capable of etching deep, narrow channels or holes in metal substrates. This is crucial for certain microfabrication applications and MEMS devices.
Controllable Etching Rate:
- The etching rate in wet film etching can often be precisely controlled by adjusting parameters such as etchant concentration, temperature, and agitation. This control is important for achieving specific etching depths or feature dimensions.
Rapid Prototyping:
- Wet film etching is suitable for rapid prototyping and small-batch production, providing a quicker turnaround time compared to some other metal fabrication methods.
Minimal Tool Wear:
- Since wet film etching is a chemical process, it does not involve physical tooling or machining. Consequently, there is no tool wear, which can be advantageous for maintaining consistent quality over time.
Environmental Considerations:
- Similar to dry film etching, wet film etching is generally considered environmentally friendly as it does not produce significant hazardous waste or emissions, particularly when using environmentally friendly developer and etchant solutions.
Integration with Other Processes:
- Wet film etching can be easily integrated into larger manufacturing processes, making it compatible with subsequent steps such as plating, passivation, or additional patterning steps.
Quality Control and Inspection:
- Wet film etching, like dry film etching, allows for rigorous quality control and process monitoring, ensuring that final components meet specified tolerances and standards.

Wet Film Precision Metal Etching Process:

Equipment:

Coater for Wet Film Resist:
- Purpose: Used to evenly apply a wet film resist onto the metal surface.
Drying Oven:
- Purpose: Dries the wet film resist after application, ensuring proper adhesion and consistency.
UV Exposure Unit:
- Purpose: Exposes the dried wet film resist to UV light through a photomask, creating a pattern on the resist.
Developer:
- Purpose: Contains a chemical solution that removes the unexposed portions of the wet film resist, revealing the metal surface beneath.
Etching Machine:
- Purpose: Selectively removes metal from the exposed areas using chemical etching solutions, creating the desired pattern.
Stripping Machine:
- Purpose: Removes any remaining wet film resist from the metal surface after etching.

Workflow:

Metal Cleaning:
- Clean the metal sheet or component to remove impurities and contaminants.
Wet Film Resist Application:
- Place the metal sheet or component in the coater.
- Apply the wet film resist evenly onto the cleaned metal surface. This resist is typically a liquid that covers the entire surface.
Drying:
- Transfer the metal with the applied wet film resist to a drying oven.
- The oven dries the resist, evaporating any solvents and ensuring that the resist adheres properly to the metal.
Exposure:
- Place the metal with the dried wet film resist under the UV exposure unit.
- Expose the resist to UV light through a photomask that carries the desired pattern. The UV light cures the resist in the exposed areas, making it resistant to etching.
Development:
- Transfer the exposed metal to the developer.
- The developer contains a chemical solution that dissolves the unexposed portions of the wet film resist, revealing the metal surface underneath. This reveals the pattern for etching.
Etching:
- Immerse the metal into the chemical etching machine containing the etching solution.
- The chemical selectively removes the exposed metal areas, leaving the protected areas intact. Etching continues until the desired depth or pattern is achieved.
Rinsing and Cleaning:
- Rinse the metal thoroughly with water or a suitable rinse solution to remove etching chemicals and residues.
Stripping (if needed):
- Use a stripping machine or stripping chemicals to remove any remaining wet film resist from the metal surface. This step ensures a clean, finished product.
Final Inspection:
- Inspect the etched metal for quality, accuracy, and adherence to specifications.
- Any necessary post-processing or quality control checks are performed at this stage.

The wet film precision metal etching process is suitable for applications where fine details and intricate patterns are required. It offers an alternative to dry film etching and is commonly used in industries such as electronics, microfabrication, and precision engineering.

If you are interested in finding out about Wet Film Metal Etching Equipment overall price. Please do not hesitate to contact us. Usually we will contact you within 2 days after we receive your information.