Photochemical Reel-to-Reel Etching 0.02mm to 0.5mm Precision Metal Parts for Filtration

At Xinhaisen, we specialize in precision photochemical reel-to-reel etching, offering a highly efficient method for manufacturing metal filter parts with extremely tight tolerances. This process enables high-precision, high-volume production of intricate components ideal for filtration systems, with a wide range of material options and customization possibilities.

Materials We Etch::

• Stainless Steel (SS) – Ideal for corrosion-resistant filters in various environments.

• Copper (Cu) – Excellent for thermal management and electrical conductivity.

• Nickel (Ni) – Great for applications requiring high durability and corrosion resistance.

• Titanium (Ti) – Suitable for high-strength, lightweight filtration parts.

• Aluminum (Al) – For lightweight, cost-effective filter applications.

• Alloys – Custom alloys can also be processed to meet specific filtration needs.

Available Dimensions and Thickness:

• Thickness Range: From 0.02mm to 0.5mm, with ultra-tight tolerances as precise as ±0.01mm.

• Width: Up to 500mm wide, accommodating different material widths for various filtration systems.

• Custom Sizes: We can produce parts in specific dimensions tailored to your exact requirements, including custom apertures and mesh patterns.

How Does Reel to Reel Photochemical Etching Work?

 flow.

1. Unwinding – The metal coil is unwound and fed into the processing line.

2. Cleaning – Surface impurities such as oils, oxides, and other contaminants are thoroughly cleaned.

3. Coating – A thin, uniform layer of photoresist is applied to the metal surface.

4. Imaging – Patterns are transferred to the photoresist via ultraviolet (UV) exposure.

5. Etching – The exposed areas of metal are chemically etched away.

6. Stripping – The remaining photoresist is stripped off.

7. Rewinding – The processed metal strip is rewound for inspection or further assembly.

This efficient process delivers high throughput, ensures consistent product quality, and reduces manufacturing costs, making it ideal for sectors such as electronics, automotive, filtration, and medical devices.

Advantages of Roll to Roll Continuous Etching

• Consistency: Achieve uniform results in every batch, even with large production runs.
• Tight Tolerances: We guarantee tolerances of ±0.01mm, ensuring your filtration parts fit and perform as required.
• Versatility: Whether you need fine mesh for air, liquid, or gas filtration, we can produce custom solutions for various filtration applications.
• Clean Edges: Our etching process results in smooth, burr-free edges, reducing the need for additional finishing.
• Eco-Friendly Process: Our photochemical etching process is clean and environmentally friendly, with minimal waste and energy consumption.

Etching Capabilities:

Our Reel-to-Reel (R2R) photochemical etching process allows us to achieve:

1. High-Precision Etching: Patterns and apertures down to micrometer levels with high accuracy.

2. Efficient Large-Scale Production: Continuous processing of metal coils enables fast, cost-effective manufacturing.

3. Complex Filtration Patterns: We can etch intricate mesh designs, precise holes, and fine features that are critical for high-performance filtration.

4. Low Material Waste: With continuous feeding and processing, the material wastage is minimal, helping to reduce costs.

Other Available Processes:

• Laser Cutting & Stamping: For additional precision after etching.

• Microchannel Etching: For fluidic or thermal management applications.

• Diffusion Bonding: For joining etched components into multi-layer structures.

• Surface Treatments: Passivation, polishing, or coating for enhanced performance.

Why Choose Xinhaisen?

• 13+ Years of Expertise: With over a decade of experience in photochemical etching, we are industry leaders in precision metal processing.

• Quality Assurance: We follow stringent quality control standards throughout the production process.

• Fast Turnaround: We offer quick lead times, whether for prototyping or large-scale production.

• Custom Solutions: We collaborate with clients to provide tailored etching solutions for their unique filtration needs.

• Global Reach: We serve industries worldwide, from electronics to automotive, filtration, and medical devices.

How to custom your metal parts by Reel to Reel Photochemical etching from us?

1. Please send us your design.
We accept the following file formats:DWG, DXF, PDF, STP, Gerber, IGES, CorelDraw and Adobe Illustrator.

2. Samples making lead time:3-10days

3. Express:By DHL, FedEx, TNT, around 3-7days.