The photo chemical etching process. A process perfected.
Creating burr-free, stress-free, complex metal components with micron-level accuracy.
We specialize in photo chemical machining. (You may have heard the same process referred to as chemical etching, photo etching or chem milling). Whatever you call it, it’s a method for fabricating even the most tiny, complex metal parts with unbelievable precision. Photo chemical machining is an efficient alternative to stamping, punching, laser or waterjet cutting, and wire EDM production.
What is photo chemical etching?
Photo chemical etching—also known as photochemical machining—is a subtractive manufacturing process that creates intricate designs and precision thin metal parts from a variety of sheet metals and alloys.
The process involves applying a photoresist (or mask) to the surface of the metal, then using a chemical spray to selectively remove the uncovered areas. The result is a permanent, burr-free image that is used to create parts of various shapes, thicknesses, and complexities.
Photo etching is a subtractive milling process, which means unnecessary portions of the raw material are removed to create your final product.
How does photo chemical etching work?
The chemical photo etching process works by printing your component design onto a photoresist mask which is then applied to sheet metal. The unprinted areas of photoresist are dissolved, exposing the metal, which is then etched away—leaving behind your component part.
First, we create a light-sensitive photoresist tooling, which we call “artwork.”
Note: Computer screen showing a part being drafted to begin the photo chemical etching process
Parts are imaged onto the metal surface using the artwork.
Note: Part and page slide out from behind the screen, get layered onto metal sheet, light flash
The metal sheets are “developed,” leaving only the part’s shape protected.
Note: Tools move away, liquid sprays or washes over the sheet, dissolving the unneeded resist
The material is sprayed with an acid solution that dissolves exposed metal, leaving the masked area behind.
Note: Liquid sprays or washes over the sheet, dissolving the excess metal and leaving just the part + remaining resist
The acid solution is neutralized and rinsed off and the artwork is stripped off.
Note: Liquid sprays or washes over the sheet, leaving only the part
The parts are cleaned, dried and inspected using our strict quality control processes.
Note: Cloth, air, and/or magnifying glass moves over the part
We pack and ship your order.
Because parts are often so small, even large orders can be sent anywhere in the world affordably.
Note: Part slides into box
Chemical etching benefits
- Cost-effective: With low setup costs and no costly wear on tools, photo chemical etching has one fixed price per design, unlike laser cutting and sheet metal machining.
- Flexibility: Low-cost design iterations to be created in hours with the inexpensive, flexible tooling of the photo chemical etching process.
- Repeatability: Chemical etching doesn’t mechanically distress the metal or cause heat distortion, allowing for high-volume production of complex, high-quality designs.
- Fast turnaround: You can expect lead-times of days instead of weeks or months with chemical etching, which doesn’t require a large team of engineers or designers.
- Burr-free parts: Accurate up to ±0.025mm, chemical etching creates precise parts that retain their fine detail and unique properties at any production volume.
- Scalability: Scale from prototype to high-volume production using a single design tooling, for accelerated lead-times without compromising quality.
Suitable for 2000+ metals
The photo chemical etching process is used to create precision parts from a wide variety of metals, regardless of their hardness and temper. Vaga Industries works with hundreds of metals, and offers savings on high-volume production due to our long-established supplier relationships.
- Aluminum
- Brass
- Copper and copper alloys
- Inconel
- Nickel and nickel alloys
- Steel and stainless steels
Components for any application or industry
Chemical photo etching is a highly versatile process. Whether you need a one-off prototype or 1,000 units, we fabricate thin metal components for common or unique applications for any industry.
- Shims
- Flat springs
- Prototypes
- Decorative Panels
- Electrical Contacts
- Encoder Discs
- XYZ
7 reasons photo etching is your #1 choice.
It’s Flexible
Photo chemical machining works with virtually any metal.
It’s Fast
From concept to delivery with some of the industry’s shortest lead times.
It’s Affordable
Low tooling costs that match the tightest budgets.
It’s Precise
Our process creates burr-free parts and doesn’t work-harden material.
It’s Limitless
Nearly any part configuration can be precisely fabricated.
It’s Scalable
Fabricate just one key element, or 100,000 of them.
