How to Work to Micron Precise Manufacturing Demands
For global industries including defence and electronics, innovation often brings challenges. The demand for miniaturisation is growing, with products needing to be smaller, lighter and more efficient without compromising performance. Add to that the expectation of absolute precision and tolerances required measured in microns and the demands on product design specialists are increasing rapidly.
Yet, for UK-based product designers competing in a global market, the challenge isn’t just about meeting high expectations. It’s about finding a manufacturing process that isn’t afraid of these precision demands while pairing it with speed and cost-effectiveness.
This is where photochemical etching steps into the spotlight. A precision manufacturing technique, it’s quietly revolutionising how designers tackle the most complex problems in fields including defence and electronics.
Facing the Global Precision Challenge
From aerospace components to consumer electronics, technology is evolving to demand unprecedented levels of accuracy on increasingly smaller scales. Take the defence industry as an example. Precision is critical when manufacturing components for surveillance equipment or onboard computer systems. A minor error could have devastating consequences. Similarly, in electronics, as devices grow sleeker, parts like camera apertures and microfilters require tolerances that cannot afford to falter – we’re talking measurements as small as 25 microns.
The biggest issue, however, is not just achieving this level of precision but doing so at a pace and price point that keeps up with global supply chain demands where price and pace are imperative.
Traditional manufacturing processes like CNC machining struggle to keep pace without ramping up costs. And as offshore manufacturing preferences increase due to extremely competitive pricing, the question for the powerhouse of UK product designers is clear: how do you retain control, precision and maintain competitive edge in global manufacturing?
Photochemical Etching as the Solution
Photochemical etching offers the ideal answer. This process allows scalable precision while remaining surprisingly affordable. It uses a photographic tool to create an image of the design on a metal sheet. A series of chemical processes then selectively remove unwanted areas of the metal, leaving the intricate details intact. For UK product designers, the benefits are numerous.
Low-Cost Tooling and Micron-Level Precision
When tolerances can be the difference between success and failure, photochemical etching consistently delivers – even to the tightest specifications, as small as ±25 microns (roughly a quarter of the thickness of a human hair). Unlike traditional methods that require expensive equipment for prototyping, photochemical etching enables quick and cost-effective changes to designs. With tooling costs as low as £95 for flat parts, this method allows for multiple iterations without budget concerns. For example, you could design a filter with precise hole sizes for material handling equipment dealing with industrial powders and refine the design easily until it meets exacting requirements.
This level of detail makes it the go-to method for industries where there’s zero room for error.
Rapid Turnaround Times
Timing is critical when working on global projects, especially when iterations are needed to meet client demands. Photochemical etching offers a typical turnaround of five working days, with an even faster rapid three-day option available. This is a game-changer for UK designers who value speed and flexibility while collaborating with international stakeholders.
Addressing the Knowledge Gap
Another lesser-known aspect of photochemical etching is its ability to shape flat designs into three-dimensional forms. Many design houses overlook this added capability, which can save significant time and costs. Beyond etching, services like heat treatment and plating ensure that the final product is ready for rigorous use. Whether designing components intended for installation on satellites or modular parts for consumer electronics, this additional flexibility opens up a wealth of possibilities.
For designers working in the UK, keeping up with global standards is a constant challenge. Photochemical etching not only allows them to produce world-class products quickly and affordably but also keeps their work at the forefront of precision manufacturing. By exploring this technique further, designers can bridge the gap between what’s expected globally and what’s achievable locally.
Achieving Precision
Preparing the Photographic Tool
The process begins with creating a sharp and accurate photographic tool. This tool is like a blueprint, holding the exact design that will be etched onto the metal. The graphics tool must be prepared with exceptional precision because even the smallest inaccuracy here can cascade through the process, jeopardising the final product. Specialists ensure the tool is cleaned thoroughly to prevent any contamination, aligning it perfectly with the intended design standards.
Cleaning the Metal
Before anything can be etched, the metal sheets undergo a thorough cleaning process. This step ensures that no traces of grease, dust or other contaminants interfere with the application of the resist coating. A cleaner base leads to better adhesion of the resist, protecting the design during the etching process. Without this diligence, even the most finely tuned chemical etching would fail to meet the strict demands of industries like defence and aerospace.
Applying the Resist Coating
Next, a light-sensitive resist is applied to the cleaned metal sheet. This coating is essential as it creates a protective layer over the areas that should remain untouched by the etching chemicals. UV light is used to expose the photographic design onto the resist, solidifying the desired pattern while the unexposed resist is removed. This stage demands absolute precision in alignment and exposure to ensure the design mirrors the original specification.
The Etching Stage
With the resist securely in place, the metal goes through the etching process itself. A specially formulated etchant is carefully applied to dissolve the exposed areas of the metal. This chemical reaction selectively removes material, leaving behind the intricate details of the design. The process is monitored and adjusted to prevent over-etching, which could compromise the final component’s accuracy.
For example, this stage proves critical when creating microfilters for industrial powders or camera apertures for sleek electronics. The precise control of the etching depth and tolerance ensures these components perform flawlessly in their applications.
Rigorous Quality Inspections
Once the etching is complete, the product undergoes multiple layers of quality assurance. Dimensional inspections validate the part’s adherence to exact specifications, while routing documents ensure that every critical stage was followed without deviation.
For those tackling increasingly complex designs, photochemical etching not only delivers solutions but sets a new benchmark for innovation.
Looking for ways to advance your designs while staying competitive globally? Explore photochemical etching and how it can meet your most demanding requirements, or contact us today for a consultation on your next project.
