Flat springs are thin and flat metal components that are designed to store and release energy when deflected. They can be used as stand-alone components or as part of an assembly in a wide variety of applications. Flat springs can be manufactured using various methods such as stamping, laser cutting, waterjet cutting, and chemical etching. In this paper, we will focus on the etching process for manufacturing flat springs.
Etching is a highly precise and efficient process that involves removing selected areas of a metal sheet to create a specific shape or pattern. The process starts by applying a photoresist to the metal sheet, which is then exposed to a UV light through a patterned mask. The exposed areas of the photoresist become insoluble, and the unexposed areas are removed during the developing process. The metal sheet is then etched in an acid solution to remove the unprotected areas, leaving the desired shape or pattern.
Difference between traditional sheet metal precision processing VS Chemical etched sheet metal processing
VECO’s video to learn what metal etching is.
Comments related to etching technology:
From @chadr2604: There is another way it involves stacking many layers of very thin material with an There is another way it involves stacking many layers of very thin material with an adhesive, pressing the stack, then either stamping or punching the blank then heating it to release the adhesive. The parts will not be as accurate the tolerance is limited to about .002″ but if its good enough its much faster.
From @chadr2604: If you try to cut that stack with a laser you will just start a fire we had an aluminum fire trying that.Modern precision sheet metal fabrication includes a common technique known as etching, which differs from traditional sheet metal fabrication in several ways. Here are some key differences between etching and traditional precision sheet metal fabrication:
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- Principle: Traditional sheet metal fabrication typically involves mechanical processes such as cutting, bending, and punching to shape and form metal sheets. Metal etching by Metal Etching Machine , on the other hand, is a chemical process that uses specialized etchants to selectively corrode the metal surface, achieving precise etched patterns and features.
- Accuracy and Complexity: Etching offers advantages in terms of precision and complexity. By controlling the composition, concentration, temperature, and etching time of the etchant, extremely fine etching can be achieved with accuracy down to sub-micron levels. Additionally, etching allows for the creation of intricate geometries, microstructures, and patterns that may be difficult to achieve using traditional mechanical methods.
- Processing Speed and Cost: Etching generally offers faster processing speeds, particularly in large-scale production. In comparison, traditional mechanical fabrication methods may require more time and cost to achieve the same level of precision and complexity.
- Materials Compatibility: Etching techniques are applicable to a range of metal materials, such as copper, aluminum, stainless steel, and titanium. Traditional sheet metal fabrication methods may have limitations when it comes to certain materials or thicker metal sheets.
- Design Flexibility: Etching provides greater design flexibility. By incorporating techniques like photolithography or screen printing during the etching process, complex patterns and structural designs can be achieved. This makes etching suitable for applications in microelectronics, optical devices, microfluidic devices, and more.
- Precision: Etching can produce highly precise and complex shapes with tight tolerances, which is difficult to achieve with stamping or laser cutting.
- Consistency: Etching produces consistent parts with uniform thickness, shape, and quality.
- No burrs: Etching eliminates the need for secondary operations such as deburring or machining, as there are no burrs or rough edges.
- Design flexibility: Etching allows for easy design modifications and customization, making it an ideal process for producing prototypes and low to medium volume production runs.
