Photo Etching Technical & Design Information

When designing your photo etched component there are certain guidelines to aid in the fabrication.  Use this page as your general guide, but don’t hesitate to contact VACCO if your specifications don’t agree with any of these general rules.

The general nature of photo etching is directly related to the material thickness.  Dimensions, Tolerances, Edge Profiles, and Configurations are directly related to the material’s thickness choice.


What Shapes Can Be Etched?

Etchable shapes are, generally, any configuration larger than the thickness of the material.

When you give us the size of your parts, we'll help you select a material that is compatible with your application. All etching is accomplished on flat surfaces. After etching, forming achieves any final three-dimensional configuration you may need.

 

What Tolerances Can Be Held?

In general, the standard minimum dimensional tolerance equals ±10% of the material's thickness (±.0005" min. tolerance). Positional tolerances are held to microns. Specific dimensional tolerances depend on three factors:

  • Type of Alloy Selected
  • Thickness of Alloy Selected
  • Pattern to be Etched
    (Lower tolerances available at increased costs)


Edge Profiles

Relationship of Bevel to Metal Thckness.

Etchant chemistry attacks all exposed material surfaces, both laterally and vertically.
VACCO can help create edge profiles that will aid in the customer’s requirements.

Panel Size/Part Size

The size of your part is limited to the size of the panel that VACCO can process through its’ complete photo etching processing.   There also may be some limitations to the width of material available from their mills. VACCO makes every attempt to fit as many parts on the available process panel as possible to lower individual unit costs.

  • Typical panel size:             18” x 28” (width often smaller based on material availability and requirements.)
  • Large panel size:               28” x 34”
  • Extra large panel size:       26” x 68”

What Kind of Materials Can Be Etched?

Common materials that can be etched range in thickness from .0005" to .125", include:

  • Aluminum
  • Brass
  • Copper
  • Carbon Steel
  • Inconel
  • KaptonTM
  • Kovar
  • Lead
  • Magnetic Alloys
  • Molybdenum
  • Monel
  • Nickel
  • Spring Steel
  • Stainless Steel
  • Alloy 42
  • Phosphor Bronze
  • Silicon Steel
  • Titanium
  • Nitinol Shape Memory
  • Beryllium Copper
  • Zirconium

Part Tabbing

VACCO recommends, wherever possible, parts be tabbed into the process sheet for consistent etching results.   If parts are not tabbed into the material sheet there may be inconsistent dimensional results during etching process.

VACCO does as well offer processing of etched components in an untabbed process sheet.   These requests are reviewed on an individual application basis.   Many parts, such as some medical implants, may require 100% burr free and this is something VACCO can address with each request.

VACCO will ship the finished components either as single pieces or tabbed into the process sheet per your preference.   Receiving parts tabbed into the process sheet provides the following advantages:

  • Improved dimensional constancy across the panel of parts
  • Process advantages for secondary processes such as plating and electro polishing
  • Higher yields due to reduced handling damage (thin, delicate parts)
  • Ease of flat sheet packaging & shipping
  • Simplified inventory control for cycle counting

Various tab configurations can be used to connect the parts into the sheet. Straight tabs are used for shearing the parts from the sheet, and “V” shaped tabs are used for flex bending to separate the part from the sheet.