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Unlike mechanical perforating methods such as punching, stamping or laser cutting, photochemical machining of metal leaves the material free of burrs and induced mechanical or thermal stress or deformation.
Rechargeable nickel metal hydride (NiMH) batteries are constructed using nickel as the positive node. The nickel electrodes, or cathodes, are grids or screens of varying configurations that are readily produced by photo etching. NiMH batteries are rapidly replacing NiCad because they do not contain toxic cadmium and offer better life cycle performance.
Very fine features can be created in stainless, moly and other alloys to allow patterned depositions for a number of electronics applications.
Applications range from heavy gauge metal effluent filtration to extremely fine thin-gauge filters and diaphragms for liquids and gasses in a variety of alloys including steel, copper, aluminum, nickel and molybdenum.
Industrial, Commercial, and Scientific Applications for Perforated Metal
Metal meshes can be chemically etched in a wide variety of alloys including steel, nickel, copper, brass, aluminum and more. Holes can be made in a variety of shapes and sizes at no additional cost in tooling.
Precision etched meshes, grids, filters and screens are used in many types of industrial, decorative and architectural applications. In many cases, chemical etching of metal meshes, grids, screens and filters provide better value and performance than woven or punched products.
Photonic Transmission Control Screen
Space Shuttle Environmental System Filter
Beryllium Copper Mesh
P3/4" In-Line Fluid Filter
Photo Etching Perforated Metal: Frequently Asked Questions
Q: What are the limitations for etched screens?
A: The minimum hole size needs to be, preferably, 120% of the metal thickness and the minimum ligature between holes is not less than the metal thickness and never less than .005 inches.
Q: What is the largest screen you can make?
A: Our equipment can process screens up to 24” x 60”
Q: What are the thinnest and thickest materials you can process?
A: .001 inches in most alloys and up to .080 inches in aluminum.
Q: How much do etched screens cost?
A: For common alloys (stainless, copper, brass, aluminum) between .010 and .020 thick, you can expect costs between .20 and .30 per square inch, assuming 120% minimum hole size.
Q: How much does tooling cost?
A: For screens up to 24” x 24”, generally, $285.00
Q: Do you have any standard screens?
A: No. Everything is made to customer specifications.
Q: Do the holes have to be round?
A: No. The holes can be virtually any shape and they don’t have to be the same shape. Any collection of shapes can be made. The caveat is that the minimum radius is equal to the material thickness and the 120% rule applies to the narrowest area of an opening.
Q: Can screens have solid borders?
Electroforming for Features Less than 25 Microns
Is Electroforming Right for You?
Learn about the process and why OEMs are turning to electroforming to fabricate ultra-precise metal parts!
Electroforming is an additive manufacturing process used in the creation of metal parts. What makes it different from plating is that rather than adding an additional layer to an existing part, electroforming allows us to create an entirely new piece particle by particle. Like etching, electroforming is widely used among OEMs with a need for miniscule yet precise component parts for their products.
In this introductory guide to electroforming, you’ll learn:
- The entire electroforming process - step by step
- The difference between electroforming and similar processes
- Design capabilities
- Modern applications of the technology