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We design and manufacture photo etching on metal components from various materials suitable for aerospace, defense, medical, electronic, filtration, automotive and many other commercial markets. Our core competency lies in producing micro-machined components, such as micro fluidic devices, screens and meshes, fuel valves, manifolds, electronic components and disc filters. Chemically Etched Miniature Systems  as well as our PhotoPore screens are two of our patented etched products which are used in critical spacecraft and medical applications.

Types of Metals We Etch

Stainless steel

Titanium

Brass

Copper

Nickel alloy

Carbon & spring steel

Nickel-Iron

Metal Photo Etching Process

Depending on the dimensions, tolerances, edge profiles, and configuration requirements, certain materials may be better suited for your needs. Our assistance is offered upon material selection. Photo etched components can be produced from panels up to 28” x 68” in size in our clean rooms, holding minimum dimensional tolerances of ±0.0005″ and even better positional tolerances. Based on your application requirements, we can process etched components in tabbed or untabbed process sheets. Our operations yield consistent etching results and dimensional consistencies across the entire panel.

At the beginning of every fabrication project, component specifications provided by customers are reviewed thoroughly and a project engineer is assigned to each job. Design assistance is also offered to customers with Autodesk Inventor, COSMOS and Ansoft Maxwell 2D. Photographic artworks are generated according to customers’ exact specifications and are laser plotted to engineered “photo tools”. The images produced by these photo tools are exposed onto resistant dry or wet films; controlled UV exposure ensures accurate transfer of images from artwork photo tools to the process panels. As one of the largest commercial etching facilities in the United States, we offer development, prototyping and high volume manufacturing capabilities.

Statistical Process Control (SPC) is used throughout our production process and chemical controls. Our SPC ensures high quality regulation of your photo etched component. Proprietary resist removal solutions are used for stripping the resistant films from etched panels. Along with our photo etching expertise, we provide many other in-house capabilities including; Automated Visual Inspection, Assembling, Testing, Diffusion and Adhesive Bonding, Forming, Special Packaging and other value added operations performed to your components, in a dust-controlled environment. As an environmentally committed organization, we recycle all acid and metal waste.

Problems Addressed with VACCO Photo Etching Metals

Engineers and procurement teams often face challenges when sourcing precision etched components for demanding applications. Common issues include:

• Difficulty achieving fine features or micro geometries with stamping, machining, or laser cutting.
• Inconsistent tolerances across large production runs.
• Burrs, heat affected zones, or mechanical stress introduced by traditional cutting methods.
• Limited material options for thin gauge or specialty alloys.
• Long lead times for prototypes or design iterations.

Photo etching helps solve these challenges by enabling complex, burr free features with repeatable accuracy across a wide range of metals.

Industries Served

Photo etched components are used across markets where precision, repeatability, and clean edge profiles are required. This manufacturer supports:

• Aerospace and defense systems
• Medical devices and surgical instruments
• Electronics and semiconductor components
• Filtration and fluid control systems
• Automotive sensors and fuel systems
• Industrial and commercial equipment
• Research, laboratory, and micro fluidic applications

These industries rely on photo etching for parts that must meet strict dimensional and performance requirements.

Photo Etching on Metal: Frequently Asked Questions

What Types of Features Can Be Produced by Photo Etching on Metal?

Photo etching on metal can create intricate patterns, micro channels, fine meshes, thin wall structures, and detailed geometries that are difficult to achieve with mechanical or thermal cutting methods.

How Large Can the Panels Be?

Panels up to 28″ × 68″ can be processed, allowing efficient nesting for both prototypes and high volume production.

Which Metals Are Compatible with Photo Etching?

Supported materials include stainless steel, titanium, brass, copper, nickel alloys, carbon steel, spring steel, and nickel iron alloys.

Does The Process Support Prototyping?

Yes. The workflow is well suited for rapid prototyping because tooling is digital and does not require hard dies, enabling fast design changes and short development cycles.

Precision Metal Photo Etching Capabilities