Creating the design of a new metal part is perhaps the most complex aspect of manufacturing operations. A lot of time goes into research for determining the suitability of materials and manufacturing processes. Budgetary constraints and project deadlines can make it even more challenging. The advent of photo etching has brought an excellent alternative to the traditional metal fabrication technologies such as water jet cutting, wire EDM, electroforming, stamping, and CNC punching.
Photo etching uses chemical etchants to clear the unwanted sections of metal that are not a part of the design. The new technology delivers a range of benefits to manufacturers, including unaltered metal properties, flexible tooling, burr-free components, reduced costs, and shorter lead times. But the success of this technology for your manufacturing business depends on its suitability for your process. Here are some factors that help you decide if photo etching is an apt choice for your manufacturing process.
You need to avoid mechanical deformations
Component integrity is a bigger concern for some industries as compared to others. It matters even more for units that produce intricate designs with high-quality specifications. If mechanical deformations are a concern for your business, photo etching is the best option for you. The traditional processes will probably not work because they are prone to deformities. Stamping and punching can cause shearing deformation, while laser cutting and electric discharge machining can lead to ablative deformation. But you will not have to worry about these issues with chemical etching, so consider it if you want to ditch deformations.
Heat-affected zones can harm the material
Heat-affected zones refer to the non-melted areas of metal whose properties are altered on exposure to high temperatures. The thermal diffusivity of the part determines the size of a heat-affected zone. Lower diffusivity translates into a wider zone size. Heat-affected zones are a serious issue for manufacturers as they can compromise the integrity and functionality of components. The risk is higher if you opt for metal fabrication processes such as plasma cutting and laser cutting. However, photo etching eliminates the possibility because it does not create thermal stresses that result in heat-affected zones. The process involves dissolving materials chemically instead of heating them.
You cannot afford burring
While mechanical and thermal stresses are concerns by themselves, they can also cause the development of burrs. These are debris made of metal particles that develop on the part’s surface during the fabrication process. Burring can interfere with the functionality of the part. They can also cause problems such as excessive friction, corrosion, and shortened fatigue life. Laser cutting is often a culprit that causes burring, specifically when the machine operates slowly. But you can switch to photo etching as it curbs the appearance of burrs and ensures a fine finish for the part.
Your materials are extremely tough
Metals vary in the degree of toughness, and the choice of fabrication process depends on the tensile strength of the metal used in your manufacturing process. For example, metal stamping is not an apt choice for facilities working with high-strength metals and alloys such as titanium. Photo etching emerges as a good option as it works well for a variety of metals, including the extremely tough ones. It comes as no surprise that Aluminum etching has gained immense popularity for industries like transportation, construction, electronics, and cookware. The technology is also ideal for materials such as stainless steel, brass, copper, chromium, and nickel.
You need consistently tight tolerances
If your manufacturing process needs consistently tight tolerances, photo etching is the right choice. Being a CAD-guided process, it is hardly susceptible to tooling fatigue which is common with mechanical tooling. Tooling fatigue gets problematic because it can create imperfections in a production run, which is the last thing you will want to deal with. You can depend on photo-chemical etching when it comes to repeatability in design. The technology promises fine and precise features that remain consistent throughout the manufacturing process.
You want to minimize tooling expenses
While creating the right tooling is vital for a robust fabrication process, it requires time and money. Metal stamping involves an expensive initial tooling outlay, which can be a pain for a manufacturing company. Moreover, tooling expenses with this technology can often go beyond the budget if you need to make design revisions and corrections later. Things are much simpler and less expensive with photo etching. Tools are created with CAD data, so alterations in the existing ones do not require much work. Businesses that want quick and low-cost prototypes can rely on the technology.
You want to prototype for a large production volume
If you are planning for the early manufacturing phase, photo etching is an excellent option. It works for prototyping as well as larger production runs. It uses compound tooling that makes prototyping cost-effective. Moreover, it is easy to change designs if they need to be tweaked. Once you finalize the design, the process can scale the volumes into higher quantities. Switching to large-scale production becomes easier than you imagine.
You have an impending deadline
Turnaround times are often a major concern for manufacturing businesses, and an impending deadline can stress you out. Choosing the right technology reduces stress as it enables you to meet the deadline without delays. Photo etching is relatively speedy, so you can create parts in weeks rather than months. It is ideal if you have to handle complicated designs and produce them rapidly. You can easily meet the deadlines without compromising quality and worrying about the cost.
Photo etching has a wide range of benefits over the traditional machining methods, making it an ideal choice for manufactures. It offers tooling flexibility and quality of parts while saving time and money. Moreover, it is more adaptive and enables quick changes in design without spending a fortune. If you have any of these concerns or expectations with your manufacturing process, you must switch to this innovative technology sooner rather than later. It is a worthy investment that makes your manufacturing operations future-ready and saves your money in the long run.