Sometimes an application requires ultra-fine micro features and tolerances that cannot be achieved with even the best controlled metal stamping process. That is where chemical etching comes into play, with the ability to create highly-repeatable, burr-free components with complex features as small as 1.2x of the material thickness.
Using a tightly-controlled reel-to-reel process enables these micro-features and intricate metal designs or shapes to be produced on a continuous metal strip using a wide variety of ferrous and non-ferrous materials, thereby facilitating the use of reeled components within automated production environments.
Among the many benefits of this reel-to-reel chemical etching process is the ability to hold very close tolerances, and extremely high level of repeatability, and true position from metal part to metal part. The degree of precision and consistency achievable offers a continuous chemically etched metal strip and a mass production advantage as compared with standard panel or sheet etching processes.
The continuous etching approach uses a “Flat-Line” process control system that continually monitors over 160 critical points in real time and maintains the process conditions within a very narrow band at all times. Coupled with ultra-precise “Chrome on Glass” photo-mask tooling, this process is exceptional at sub-micro apertures in high density metal applications.
Continuous chemical etching enables customers to design burr-free, precision metal components with ultra fine pitches, intricate shapes and 3-D feature profiles, that are unavailable using traditional metal stamping processes.
Chemically etched parts can be produced in a high volume environment which reduces tooling and production costs, while improving time to market.
Reel-to-reel etched parts can be presented to other automated manufacturing processes such as forming, plating, insert molding and assembly on a reel, further reducing total manufacturing costs.
Continuous reel-to-reel chemical etching has become a key process for implementing a wide range of complex micro-featured components for many automotive, medical, communications, filtration and other applications that demand ultra-fine precision and high reliability
To learn more about reel-to-reel chemical etching, you can visit us at the upcoming Design & Manufacturing Midwest expo, October 15-16, 2014 in Schaumburg IL - - Booth 710.
