In today’s interconnected world, the demand for electronic devices and systems is rapidly increasing across all industry sectors. Consequently, electronic component manufacturers face the challenge of selecting the most efficient and cost-effective manufacturing processes that guarantee optimal performance. Here are five reasons why MET Manufacturing Group believes electronic manufacturers should use etching:
1. Material Versatility
Etching is a versatile process that can work with almost any metal, making it an ideal choice for creating electrical components. Unlike traditional machining methods such as stamping and laser cutting, which may encounter challenges when dealing with hard, soft, or brittle metals, etching is not limited by the properties of the materials used.
Copper: Known for its excellent electrical conductivity, copper is widely used in electrical components. Post-process plating can improve its corrosion resistance.
Beryllium Copper (BeCu): This highly conductive copper alloy is durable and easy to form post-etching, making it ideal for electrical contacts.
Brass: A copper and zinc alloy known for its high electrical and thermal conductivity, strength, and corrosion resistance. It’s ideal for contacts, connectors, and busbars.
Phosphorous Bronze: This bronze alloy has superior spring qualities, high fatigue strength, excellent formability, and high corrosion resistance, making it great for battery contacts and springs.
Nickel Silver: Used in EMI/RFI shielding, this copper, nickel, and zinc alloy is known for its high corrosion resistance and solderability.
Steel: While not as conductive as other materials, tin plating can significantly enhance its conductivity and solderability. Cold-rolled steel is known for its strength and high formability.
Stainless Steel: Highly resistant to corrosion with excellent thermal conductivity, making it popular for precision metal shims, springs, and filters.
2. Zero Thermal Stress
The high temperatures associated with traditional machining methods can cause material deformities due to thermal stress, impacting the performance of the metal component. Chemical etching eradicates the potential of parts being affected by thermal stress. The process dissolves the metal parts simultaneously rather than at localized points of contact, unlike laser cutting and wire EDM, which can introduce thermal stress along the edges.
3. Zero Burrs or Micro Burring
Traditional machining processes can leave burrs that negatively impact the performance of electrical components. For example, laser cutting can leave micro burrs on the metal’s surface, while stamping can leave partial burring. Even slight burring can cause issues such as electrical short circuits, interference interruptions, plating build-up at the component’s edges, decreased formability, inaccurate dimensional tolerances, and scratches on the surface that can affect mating components. Photochemical etching dissolves unwanted materials on a molecular level, resulting in smooth surfaces and a precision-etched profile, eliminating the need for secondary deburring operations.
4. Suitable for Thin Materials and Complex Designs
As electronic devices become progressively smaller, there is a need for small-scale, lightweight components with complex designs. These microelectronic parts are usually machined from thinner metals and require tighter dimensional tolerances. Chemical etching is the optimum process for producing microelectronic components with complex patterns such as lead frames and filters. This process enables the simultaneous machining of features such as holes and slots, saving time and money compared to alternatives such as laser cutting, wire EDM, and stamping. Additionally, chemical etching offers the ability to partially etch a metal surface, creating fold lines valuable for components requiring forming.
5. Easy to Modify Tooling and Rapid Prototyping
The ability to test and modify designs cost-effectively is essential in the prototyping stage. Chemical etching makes it easy to revise electronic parts using low-cost digital photo-tooling. The process also allows for multiple-part designs that require the same material and thickness to be placed on the same tooling, reducing costs and lead times.
Summary
Chemical etching is a highly versatile and innovative process that electronic component manufacturers should consider for creating a wide range of electronics and microelectronic components. The process offers a variety of metal etching material capabilities, is resistant to thermal stress, remains burr-free, is suitable for thin materials and complex designs, and allows easy modification of tooling and fast prototyping. By taking advantage of these benefits, manufacturers can select the most efficient and cost-effective manufacturing processes that guarantee optimal performance.
Metal etching also known as chemical etching or photochemical machining is a subtractive manufacturing process that removes material from metal sheets to create intricate patterns, designs, or components. It allows you to produce complex shapes or create fine details without the need for traditional machining processes, like milling or stamping. This process is designed for various industries where high precision and fine details are crucial, including electronics, aerospace, medical, and automotive.
However, metal etchings resulting component is only as good as the manufacturer. Thus, is crucial to choose the right partner to guarantee your project’s success.
MET Manufacturing Group prides itself on setting the industry standard for precision manufacturing since 1988. We specialize in cutting-edge photochemical etching on various metals, from high-conductivity coppers to robust spring steels. Below, we discuss key factors to look at when selecting a metal etching partner and the top reasons why MET Manufacturing Group is the best choice for businesses in various industries.
Things To Consider When Choosing a Metal Etching Partner
A good metal etching partner can help streamline your process. Here are several key factors to consider when making this important choice:
1. Expertise and Experience
Look for a company with a proven track record and a wealth of experience in metal etching. An experienced manufacturer is more likely to have encountered diverse challenges and is better equipped to handle complex projects with precision. From the quote phase to final order delivery, you should feel a sense of professionalism, support, and confidence when working with your etching provider.
2. Technological Capabilities
Metal etching processes have evolved with advancements in technology. A reputable manufacturer should invest in state-of-the-art equipment and technology to ensure accuracy and efficiency in the etching process. The common manufacturer of etching equipment is Chemcut Corporation, who has been manufacturing etching equipment since 1956.In addition, your etching partner should have robust inspection equipment to certify the products being produced. MET utilizes Keyence measurement technologies that allow for accurate and quick dimensional conformity.
3. Material Compatibility
Different projects may require the use of specific metals or alloys. Ensure that the metal etching manufacturer you choose has expertise in working with the materials relevant to your application. In addition the manufacturer should have accessibility to the right materials required along with using reputable material sources. Shoot for companies to lean on RoHS and DFARS compliant materials. The right partner should also be able to handle the rare materials required by your project or offer guidance on the best options to consider.
4. Quality Control Measures
Quality control ensures that each component meets the desired specifications. Inquire about the manufacturer’s quality assurance procedures, including inspection processes, testing protocols, and adherence to industry standards. A reliable metal etching company will have comprehensive steps in place to deliver consistently high-quality products. Seek a partner who is ISO 9001:2015 certified. This common industry standard displays the company complies to a standard that will allow for a positive customer experience and ensures the demands of your project will be met at all levels of delivery, from prototype to production.
5. Customization Options and Value Added Services
Every project is unique, and customization may be a critical factor in your decision-making process. A reputable metal etching manufacturer can offer tailored solutions to your design and size requirements. The value added services are also important as you may want to utilize a service like selective plating or forming as your project evolves. Work with a manufacturer who has the bandwidth to offer these valuable services and drive the best performance to your product.
6. Customer Reviews and Testimonials
Before finalizing your decision, research customer reviews and testimonials to determine the satisfaction levels of past clients. Positive feedback and success stories can provide valuable insights into the manufacturer’s reliability, professionalism, and overall capability.
Why Choose MET Manufacturing Group
MET Manufacturing Group is a trusted name in the industry. In addition to the above core qualities, here are unique factors that set us apart:
Great Value on Price vs. Quality
MET Manufacturing Group emphasizes delivering unparalleled value, striking the perfect balance between competitive pricing and uncompromised quality. This commitment ensures that clients receive exceptional metal etching services without breaking the bank.
Dynamic and Experienced Engineering Team
We boast a dynamic and experienced engineering team trained in the latest programs, projects, and designs. The team’s proficiency and adaptability play a crucial role in overcoming challenges, offering innovative solutions, and successfully realizing clients’ intricate design specifications. Our engineering team interfaces directly with our customers to deliver the results you expect from your project.
Short Lead Times
MET Manufacturing Group takes pride in its ability to provide short lead times, with a typical turnaround of 3-4 weeks. This ensures that you meet project deadlines and ensures a streamlined transition from design to the production phase.
Fast Customer Service
Our team understands the importance of responsive and efficient customer service throughout the project lifecycle. We are committed to fostering a seamless and transparent client experience, from providing quick quotes to prompt acknowledgments, timely invoicing, and clear customer communications. MET performs daily quote review with typical quote turnaround times of 24-48 hours.
Convenient Midwest Location
Situated in the heart of the Midwest, MET Manufacturing Group offers a strategic location that facilitates convenient shipping to either coast via UPS or FedEx. This ensures reliable and cost-effective product delivery while providing accessibility and ease of collaboration with clients nationwide.
Redefine Your Metal Etching Projects With MET Manufacturing Group
At MET Manufacturing Group, we have a rich background in serving multiple industries across the country. Our goal is to constantly exceed client expectations and industry standards in quality, cost, and delivery. If you don’t have a design in mind, we also have an Etching Design Guide to optimize your project for success. With our ISO 9001:2015 certification and American Systems Registrar accreditation, we guarantee only the best solutions for your needs.
