5 Phases of Chemical Etching

Precision Photo-Fab uses photographic imaging and Computer Aided Design (CAD) to manufacture precision thin (.0005" to .062") flat parts. PPFI's process is a complex, ecologically safe, and cost effective method of manufacturing thin-metal components.

Chemical Etching (or Milling), whether it is a 1,000,000 piece order, or a one-piece prototype, is technologically superior to other methods of production.

PPFI's processes are capable of producing high yields while maintaining consistent precision to +/- 0.001".

The Chemical Etching process consists of 5 phases - Precision Photo-Fab employs experts in each phase to help ensure precision products.

Computer Aided Design (CAD)

We start with a customer's sketch or drawing. PPFI uses these drawings to input the dimensions into our computerized system. This system drives a laser plotter with extraordinary accuracy to produce final artwork that is used to manufacture the parts.

Nesting these computer images allows Precision Photo Fab to effectively utilize all the available space on a sheet of metal, decreasing waste and lowering costs. The plotted artwork created from the computer is then inspected for total compliance to specifications. Engineering revisions or modifications can be made quickly and inexpensively.

The selected metal is cut to the corresponding size and meticulously cleaned. It is then laminated on both sides with a thin photosensitive material (Photo Resist).

The coated metal is then inserted between the two pieces of positive film (mechanical artwork) on a vacuum frame. The positive film is pin registered to ensure proper registration from top to bottom. Both sides are then exposed under ultra violet lights, establishing which areas of the metal are retained and which areas will be etched away.

After the metal or alloy has been exposed, it is passed through a developing unit where any unexposed Photo Resist is removed by a developing solution. Each piece is then inspected to ensure there has been no image distortion.

The developed metal is processed through a chemically controlled bath on a conveyorized etcher. As the acid attacks the metal, the parts are etched into individual pieces, or left tabbed in sheet form for secondary operation handling.

To ensure the highest quality, all parts go through a rigorous "in-process" inspection after EACH phase. This allows us to guarantee the highest degree of quality and ensures higher yield in production.

Our "end-process" inspection further guarantees total compliance to the original design using numerous inspection devices. Production quantities are also monitored using a Statistical Process Control System (SPC).

PPFI's chemical milling process is environmentally friendly. All metal and acid waste is transformed through, and treated with, a suitable polymer or polyelectrolyte. This causes the water to separate from the waste, creating a "sludge" that is then pressed into blocks suitable for safe disposal.