Chemical Etching
Metal Fabrication
Mature products have established standards, but new products do not. Every decision, from material choice to part geometry to scale-up, carries a risk. That is where engineering depth matters and where the right manufacturing process can shift timelines and risk.
Many engineers know stamping and laser cutting well, but few have worked with Photochemical Machining (PCM). That gap can slow programs or add cost. Closing it early helps products launch cleaner and faster.
PCM works by utilizing a photo-patterned resist and controlled chemistry to remove metal. There is no rigid tooling, no heat distortion, and no burrs that need cleanup. The process produces sharp features and keeps thin metals flat. Because tooling is printed in-house from a digital file, design revisions move straight from CAD to production. That speed makes PCM especially useful in prototyping, where design changes happen often.
Below are common pitfalls seen in new programs, plus practical ways to avoid them:
Passing drawings without context is risky. A part number and tolerance callouts only tell part of the story. What’s missing is why the features matter. Without that, you invite delays and rework.
A true partner will ask about operating conditions. Will the part see fluid exposure? Thermal cycling? A stacked assembly? They’ll also look at how it fits into a larger system. Those details inform decisions about material, thickness, coatings, and even packaging. A short conversation upfront can save weeks later.
How PCM adds value here: Because phototools are quick to produce, multiple design variations can be tested in parallel. Instead of guessing, engineers get real performance data to guide the final design. This speeds learning and reduces risk before production scales.
Teams often tighten everything “just in case.” This inflates cost and increases lead time. The inverse happens, too. A vital feature gets casual treatment, and performance drops.
Examples make this clear. Unneeded tight tolerances on noncritical features waste money. On the other hand, flow field geometry in hydrogen or electrolyzer plates is mission-critical. Poor channel design can trigger turbulence, pressure deltas, and uneven distribution. As a result, the output suffers.
How to fix it: Rank features by impact on function. Tag must-hold geometries and surfaces. With PCM, you can vary channel widths, land ratios, or port shapes across a test set and get quick results. Data guides the final spec.
3) Ignoring assembly and fit at scaleA single plate can look perfect on a bench. Problems appear when hundreds are stacked with gaskets, frames, and fasteners. Holes that “fit” in one part may drift across a stack. A minor edge bow can create leaks under compression.
What to do: Design with assembly in mind. Define datums that align with fixtures and gaskets. Build pilot stacks early and measure. In PCM, parts come off flat and burr-free, which helps seals and alignment. Registration features can be etched into the part to aid stacking and orientation.
Material decisions are often made based on what is on the shelf today. That can backfire. Some alloys, tempers, thicknesses, or coil widths are easy to buy in a sample size but become impractical in repeated small lots. The reverse can also happen. Picking a grade that only ships in mill-run volumes blocks the early ramp.
How to stay out of trouble: Map material availability for prototype, bridge, and full production. Confirm coil widths, thickness range, and surface finish in all phases. PCM runs well with a wide set of alloys and thin metals. That flexibility helps, but planning still matters.
A single prototype might pass every inspection, but stacks tell a different story. Cumulative error across plates and membranes can cause misalignment, reduce contact area, and change flow or heat paths. Seal lines that look fine on one unit can leak in production.
How to prevent it: Do a stack study. Model the worst-case scenario. Build a short run and measure the stack, not just parts in isolation. PCM’s burr-free edges and stable flatness reduce sources of error. Pair that with well-defined datums and consistent fixturing, and you protect yield.
Prototypes drawn without a view of process capability run into delays. A slot that is ideal for a laser may be less ideal for etching, and vice versa. Corner radii, aspect ratios, and minimum webs differ by process.
What to do: Integrate early reviews. Ask, “What is easy for PCM?” “What is expensive?” “What features get free complexity with etching that would penalize a stamped tool?” In many cases, PCM handles fine channels, micro-features, and delicate webs with speed and repeatability. Knowing that upfront can reshape the design for better function and lower cost.
A perfect part can still fail if it arrives bent, scratched, or dirty. Thin metals need support, edges need protection, and etched channels and gasket grooves must stay pristine.
Plan it: Define packaging alongside the part. Consider separators, tabs, and lift points. Think about cleanroom or controlled environments if surfaces are sensitive. Prototype packaging for a handful of parts will differ from production packaging for hundreds, so plan for separation, stackability, and protective delivery methods early.
Switzer lives in this space every day. The team brings engineering insight, process know-how, and PCM’s fast iteration cycle under one roof. For new products, that mix shortens the path from idea to stable production.
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