General Process & Basics Archives

What is photochemical etching and how does it work?

Photochemical etching is a subtractive manufacturing process. A sheet of metal is coated with a light-sensitive photoresist, exposed to UV light through a patterned phototool, and developed so that selected…

How Precise is Photochemical Etching Compared to Other Methods?

It achieves tolerances of +/-0.001”(+/-.025mm) in thin foils, and typically +/-10% of the metal thickness. This rivals laser cutting in accuracy while avoiding heat distortion, and is more precise than…

What Thickness of Metal Can Be Etched?

Standard range: 0.001”–0.040” (25 µm – 1.0 mm). In some cases, partial etching can extend to thicker materials up to 0.080”.

Can Both Sides of a Sheet Be Etched at Once?

Yes. Double-sided etching uses aligned phototools on both sides of the sheet to create channels, cavities, and through-features with tight registration.

What Level of Detail and Complexity Can Be Achieved with Photochemical Machining?

Extremely high detail is possible, including fine meshes, microfluidic channels, logos, and complex geometries. Complexity does not significantly increase cost, unlike stamping or machining.

How Small Can Etched Features Be?

Etched openings can be as small as 0.004” (100 µm), depending on material thickness. Rule of thumb: minimum feature size ≈ material thickness.

How Strong Are Etched Parts Compared to Stamped or Cut Parts?

Etched parts retain full tensile strength of the base metal because no mechanical stress or heat is introduced. Stamped parts may show work hardening or micro-fractures at edges.

Can photochemical etching create 3D parts, or is it limited to flat sheets?

Etching itself produces flat parts, but these can be bent, formed, welded, plated, or assembled into 3D structures. Half-etching can be used to define precise bend lines.

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