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PCB

How Chemical Etching Machines Work in PCB Manufacturing

Spray vs. Immersion Systems: Pros and Cons

Spray systems and immersion systems are the two primary types of chemical etching machines used in PCB production. Each has its own set of advantages, depending on the complexity of the design, required speed, and precision.

Chemical Etching Equipment Process Demonstration for Optimizing Metal Surface Adhesion
PCB Chemical Etching Machine Structure
FactorSpray SystemImmersion System
Etching SpeedFaster due to efficient liquid flowSlower but more consistent over larger surfaces
UniformityMore uniform for smaller, complex designsLess uniform, can be affected by agitation and time
Material CompatibilityBest for fine-line, high-density designsSuitable for thicker substrates, multi-layer PCBs
CostHigher initial investment, more maintenanceLower initial cost, easier maintenance
PCB Chemical Etching Machine Structure

Etchant Chemistry: Ferric Chloride, Ammonium Persulfate

Chemical etchants are key in achieving precise and clean PCB etching. Commonly used etchants include Ferric Chloride and Ammonium Persulfate.

  • Ferric Chloride: Typically used for single-sided PCBs, offering good control over the etching process but requires precise temperature regulation.
  • Ammonium Persulfate: Ideal for more complex, high-precision designs like HDI PCBs. It’s gentler on copper surfaces and yields sharper etching lines.

Temperature and Pressure Control Mechanisms

Maintaining optimal temperature and pressure is crucial for achieving high-quality etching results.

Pressure gauge: Green and red in the pressure gauge represent the normal pressure range
  • Temperature: Generally maintained between 40°C to 50°C to ensure consistent etching and to avoid over-etching.
  • Pressure: Adjusted to maintain even chemical distribution during the etching process, particularly in spray systems.

Optimizing Etching Speed and Uniformity

The etching speed and uniformity are key factors in precision PCB manufacturing. Speed is controlled by adjusting:

  • Etching solution concentration
  • Temperature and pressure
  • Substrate type and thickness

Uniformity is ensured by maintaining consistent flow rates in spray systems or the immersion depth in immersion systems.

Nozzle Design for Consistent Spray Patterns

In spray systems, nozzle design plays a critical role in ensuring uniform spray patterns. Optimal nozzles distribute etchant evenly across the surface to minimize uneven etching and defects.

Real-Time Monitoring with IoT Sensors

Modern chemical etching machines are increasingly incorporating IoT sensors for real-time monitoring. These sensors track variables such as temperature, pressure, and etchant concentration, providing instant feedback and facilitating immediate adjustments.

Material Compatibility for Multilayer PCBs

For multilayer PCBs, it’s important that etching machines handle various materials like Copper, FR-4, and high-frequency substrates. The etching system must be material-specific to ensure accurate and clean etching, especially when dealing with sensitive materials.

Handling Copper, FR-4, and High-Frequency Substrates

  • Copper: Requires etchants that offer precise control to avoid damaging traces.
  • FR-4: A common PCB material that needs precise etching to preserve structural integrity.
  • High-Frequency Substrates: These materials require specialized etching systems to maintain signal integrity and minimize losses.

Etch Factor Control for Fine Traces (<3 mil)

For fine traces (<3 mil), etch factor control is essential. The etch factor determines the width-to-depth ratio of the etch and is crucial for creating high-precision circuits. Close monitoring and adjustments to etching time, solution concentration, and temperature help maintain optimal etch factor values.

Integration with Other Wet Processing Equipment

Chemical etching machines are typically integrated with other wet processing equipment in a PCB manufacturing line, such as cleaning lines (acid/alkaline) and plating systems. This integration ensures that the PCB is thoroughly cleaned and plated after etching, resulting in a finished product with high electrical performance and structural integrity.

Wet Processing EquipmentFunction
Cleaning Lines (Acid/Alkaline)Removes residual etchant and prepares the board for plating
Plating / PTH SystemsDeposits metal layers onto the PCB after etching

Case Study: High-Density Interconnect (HDI) PCB Production

HDI PCBs are particularly challenging to manufacture due to their small traces and fine vias. A case study focusing on the production of 20μm line width PCBs demonstrates the precision of chemical etching machines in creating high-density interconnects with remarkable accuracy.

Example: A leading PCB manufacturer used Ammonium Persulfate etching to produce HDI PCBs with line widths under 20μm, significantly improving their electrical performance and signal integrity.

PCB

Chemical Etching Stainless Steel: Precision, Efficiency, and Industrial Uses

Chemical etching is a widely used process in the manufacturing industry for producing intricate patterns and designs on stainless steel surfaces. This technique offers a high degree of precision and efficiency, making it a preferred choice for industries ranging from aerospace to medical device manufacturing.

Computer motherboard, electronic components on circuits board, printed electronic board(PCB). Close up of Electronic Circuits in Technology on Mainboard(Main board,cpu motherboard,system board or mobo

What Is Chemical Etching Stainless Steel?

Chemical etching, also known as chemical milling or photochemical machining (PCM), is a process that uses acid-based solutions to selectively remove material from a stainless steel surface. This is often done to create detailed, high-precision patterns without the need for mechanical cutting tools. Unlike traditional methods, chemical etching can produce designs with tight tolerances, intricate geometries, and burr-free edges, which are especially crucial in industries like aerospace, automotive, and medical devices.

Metal Wet Etching White PaperDownload

Definition and Core Principles

Chemical etching of stainless steel involves several key principles:

  • Precision: Highly detailed and intricate designs can be achieved.
  • Efficiency: The process is faster and often more cost-effective than mechanical cutting methods.
  • No Material Stress: Unlike mechanical cutting, chemical etching does not introduce stress or distortion to the metal.
  • Environmentally Friendly: The process can use less energy and produce less waste compared to traditional machining.

How Acid-Based Etching Works on Stainless Steel

Acid-based etching solutions, such as Ferric Chloride or Nitric Acid, are applied to the stainless steel surface after the desired pattern is created using photolithography. The chemical solution dissolves the unmasked areas of the metal, leaving behind the etched pattern. This process is highly controlled to ensure precise etching and prevent over-etching.

Key Advantages Over Mechanical Cutting

  • Intricate Details: Unlike laser or mechanical cutting, chemical etching can achieve extremely fine and detailed patterns.
  • Burr-Free Edges: The process produces clean edges without the risk of burrs, reducing the need for additional finishing work.
  • No Tool Wear: Unlike mechanical cutting, which involves tool wear, chemical etching remains consistent throughout the process.

Step-by-Step Process Breakdown

The chemical etching process follows a well-defined sequence of steps to ensure accuracy and quality.

Material Preparation (Cleaning, Coating)

Before etching, stainless steel surfaces must be cleaned to remove oils, dirt, and oxidation. This ensures that the etching solution can properly react with the material. A light coating, such as photoresist, is then applied to protect areas of the metal that will not be etched.

Photolithography and Mask Alignment

Photolithography is used to create precise patterns on the material. A mask or photoresist layer is applied to the stainless steel, and UV light is used to expose the areas that need to be etched. The unexposed sections are then washed away, leaving the desired pattern behind.

Etching Solutions (Ferric Chloride, Nitric Acid)

Ferric Chloride and Nitric Acid are commonly used etchants for stainless steel, depending on the desired results. These solutions dissolve the exposed metal in a controlled manner, creating the precise etching pattern.

Post-Etching Treatments (Passivation, Rinsing)

Once etching is complete, the metal undergoes post-etching treatments. Passivation helps to enhance the metal’s resistance to corrosion, while thorough rinsing removes any remaining etching chemicals to ensure a clean and finished product.

Material Compatibility and Selection

Different grades of stainless steel offer unique properties that make them suitable for various applications. It’s important to select the right material for etching to achieve the desired quality and performance.

Best Stainless Steel Grades for Etching (304, 316, 430)

  • 304 Stainless Steel: Offers excellent corrosion resistance and is ideal for a wide range of applications.
  • 316 Stainless Steel: Known for superior corrosion resistance, particularly in marine environments.
  • 430 Stainless Steel: Provides good formability and is commonly used for decorative applications.

Thickness Guidelines (0.1mm to 2.0mm)

Chemical etching is effective for a range of material thicknesses. Stainless steel sheets from 0.1mm to 2.0mm are typically used, with thinner gauges providing greater precision for more intricate designs.

Surface Finish Options (Brushed, Mirror, Satin)

The surface finish of the stainless steel can impact both the etching process and the final appearance. Popular finishes include:

  • Brushed: Provides a smooth, matte finish.
  • Mirror: High gloss, reflective surface.
  • Satin: A soft, semi-gloss finish.

Industrial Applications of Etched Stainless Steel

Chemical etching is employed across many industries, thanks to its ability to create precision components with complex designs.

Aerospace (Fuel Cell Components, Sensor Meshes)

In aerospace, etched stainless steel is used for manufacturing components like fuel cell parts and sensor meshes that require high precision and durability in extreme conditions.

Medical Devices (Surgical Tools, Implant Markings)

Medical devices such as surgical tools and implant markings benefit from the high precision and biocompatibility of etched stainless steel.

Automotive (EMI Shields, Decorative Trims)

Automotive applications, including EMI shields and decorative trims, use chemical etching to create lightweight, durable parts with intricate designs.

Solving Common Etching Challenges

While chemical etching is a highly effective method, there are certain challenges that need to be addressed for optimal results.

Over-Etching and Undercutting Prevention

Over-etching occurs when the etching solution penetrates beyond the desired areas, while undercutting refers to the removal of material beneath the mask. Both can be prevented through careful control of time, temperature, and chemical concentration.

Burr-Free Edge Requirements

Achieving burr-free edges is one of the key advantages of chemical etching. However, if not controlled properly, the etching process can leave small unwanted projections. Ensuring the right etching conditions and solution strength helps avoid this issue.

Environmental Compliance (Waste Acid Disposal)

Proper disposal of etching solutions is essential to meet environmental regulations. Etching operations must implement appropriate waste management systems to neutralize and safely dispose of used chemicals.

PCB

Best Methods for Manufacturing Coffee Filter Nets with Precision and Cost Efficiency

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:

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:

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:

Summary Table

MethodEquipment Costs (USD)Production CostsMaintenance Costs (Annual)Flatness IssuesBest Suited ForRecommended Manufacturer
Laser Cutting$100,000 – $500,000Higher$5,000 – $10,000Thermal deformationPrecision cutting for complex designsTrumpf (trumpf.com)
CNC Machining$150,000 – $600,000Higher$10,000 – $20,000Clamping-induced deformationHigh precision and complex shapesHaas Automation (haascnc.com)
Chemical Etching$50,000 – $150,000Low$3,000 – $5,000NoneHigh-volume, fine mesh productionDragon etching (dragonetching.com)
Mechanical Stamping$100,000 – $500,000Low$2,000 – $5,000Deformation from stampingLarge-volume production of simple designsAIDA Engineering (aida.co.jp)
Electropolishing$30,000 – $100,000Low$5,000 – $10,000NoneSurface finishing and corrosion resistance improvementMacDermid 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.

PCB

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

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?

  1. 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.
  2. 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.
  3. 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.
  4. 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 EtchingDownload

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:

FPCB, PCB, Pcb Cleaning Solution, PCB Etching solution

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

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.

Huawei Mate XT

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:

  1. Laminators (for applying copper-clad film)
  2. Photoresist Coaters (dry film or liquid)
  3. LDI Exposure Machines (for circuit pattern imaging)
  4. Chemical developing machine (to remove unexposed photoresist)
  5. Chemical Etching Machines (ferric or cupric chloride)
  6. Chemical Stripper Machine (for removing remaining photoresist)
  7. Chemical Cleaning Machines (for post-etching and stripping)
  8. Dryers (to eliminate moisture)
  9. Coaters and LDI for Solder Mask (optional)
  10. Surface Treatment Equipment (for solderability)
  11. Cutting Machines (laser or CNC for profiling)
  12. 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

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:

  1. Cleaning: The metal surface is thoroughly cleaned to remove any grease, dirt, or oxides, ensuring a pristine surface for etching.
  2. Masking: A photoresist or protective mask is applied to the metal. This mask will protect areas that are not to be etched.
  3. 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.
  4. Etching: The exposed metal is immersed in a chemical etching solution, which dissolves the unmasked areas, creating the desired design.
  5. Mask Removal: Once etching is complete, the protective mask is stripped away, leaving the final etched design.
Dragon etching machine

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 FactorChemical EtchingLaser 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: $800Electricity: $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

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.

printed circuit. layout of tracks.

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

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 NameEstimated PricePurpose
Stainless steel electro Cleaning line$4500/mCleans stainless steel using specific water quality standards.
Manufacturer: DragonEtchingdragonetching.com
Stainless steel electro Painting and drying line$4500/mApplies and dries paint with precise temperature control.
Manufacturer: DragonEtchingdragonetching.com
Exposure line$18,000-$3,0000Uses LED or LDI for high-precision exposure.
Manufacturer: DragonEtchingdragonetching.com
Developing line$4500/mDevelops the exposed stainless steel accurately.
Manufacturer: DragonEtchingdragonetching.com
Stainless steel electrochemical etching line$4500/mPerforms the main etching process using copper chloride etchant.
Manufacturer: DragonEtchingdragonetching.com
Stainless steel electro Stripping line/Strips away unwanted material post-etching.
Manufacturer: DragonEtchingdragonetching.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 SeriesEtching Temperature (°C)Etchant Concentration (%)Estimated Etching Depth (µm)Etching Quality
304451850High
316482055Very High
430421745Medium
201441950High
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

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. 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.
  6. 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

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:

  1. 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.
  2. 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.
  3. 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.
  4. 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.
  5. Mask Removal: The protective mask or resist material is removed from the workpiece, revealing the final part with the desired shape and features.
  6. 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 ProcessWet 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