Photo etching is part of a spectrum of metal fabricating processes that include stamping, CNC punching, laser cutting, water jet, and wire EDM.
A quick view of key differences:
Process | Tooling | Set up | Volume | Process |
Stamping | $$$-$$$$$ | Physical | Thousands to millions | One strike |
CNC Punching | $$-$$$ | Physical & Programming | Dozens to tens of thousands | Multi-strike |
Etching | $ | N/A | Dozens to tens of thousands | Concurrent |
Laser/ Water Jet | N/A | Programming | Dozens to a few thousand | Linear |
CNC Wire EDM | N/A | Programming | Dozens to hundreds | Linear |
Key Features
Stamping utilizes hardened steel dies in the exact shape of the part and creates the part in a single strike of the die. The die costs can run from hundreds to tens of thousands of dollars and may take months to build.
CNC Punching utilizes standard die sets in a variety of configurations under computer control to create various features of a part. It may take a number of automated tool changes and a multiple of strikes to produce the part. Individual dies are generally less than a thousand dollars, but many may be needed. Generally, dies are available in a matter of days to weeks.
Photo Etching utilizes a film based phototool to transfer the images of the parts on to metal. All of the features of the part are created simultaneously in a single pass through the etching machine. It takes exactly the same amount of time to produce a simple part like a washer as it does to produce a complex part like a screen. Phototools are typically less than $500 and can be created in a day.
Laser Cutting utilizes a guided beam of high-power coherent light to burn through the metal. The laser beam traces each feature of a part, just as you would with a pencil. Depending on the material and thickness, typical lasers will cut 200-300 linear inches per minute. The time to produce a part is determined by the complexity of the design. There is no tooling required but the parts must be programmed into the laser.
Water jet cutting is very similar to laser, however the rate is slower and the cutting agent is a high-pressure slurry of water and abrasive.
CNC Wire EDM utilizes a copper wire electrode to burn through metal by arcing an electric current between the electrode and the work object. Typically, multiple layers of metal are clamped together so multiple parts can be cut. This is a relatively slow process, particularly compared to laser and water jet. No tooling is required, but programming is.
Versatility of Etching
Range of Metal Gauges
Etching is particularly suited to very thin gauge metals, routinely to .001″, that are less easily handled by other methods. We can also etch ferrous alloys up to .040”, cuprous alloys to .065” and aluminum to .080”
Includes Specialty Alloys
Alloys, including aluminum and copper, that are not readily processed by lasers are routinely processed by etching. We also etch molybdenum, indium, manganin and a wide variety of nickel alloys, including iron-nickel-cobalt used in glass-to-metal sealing applications.
Complexity and Fine Detail Made Easy
Etching handles complex geometries and multiplicities of holes far more efficiently than punching, laser or EDM. In etching, all of the features happen simultaneously.
Very fine details and very small holes are possible in etching. The minimum limits of feature and hole size are determined by the metal thickness. Holes must be at least 110% of the metal thickness and minimum metal features must be at least equal to the metal thickness.
Fast and Inexpensive Tooling
Tooling is very inexpensive, generally less than $500, and can be produced in 24 hours. Quantities can run from a few to tens of thousands. We routinely work with projects that are destined for stamping, and we may produce 100,000 parts before the conversion.
Full Service Supplier
Conard also provides a full range of services that may include forming, welding, heat treating, and a complete selection of metal finishing options as may be needed. We are AS9100/ISO 9001 and ITAR registered.
Contact Us for More Information
Conard Corporation
101 Commerce Street
Glastonbury, CT 06033
860-659-0591
860-659-8705 (fax)
sales@conardcorp.com
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