OEM/ODM Custom Photo-Chemical Etching Metal Mesh With Fast Prototype & No Tooling Cost

OEM/ODM Custom Photo-Chemical Etching Metal Mesh With Fast Prototype & No Tooling Cost

Product Overview

Xinhaisen precision metal meshes are high-performance parts manufactured through a photochemical etching process. Unlike traditional woven wire cloth or mechanically punched meshes, our etched meshes are created by chemically dissolving precise patterns into flat metal sheets. This process results in burr-free, stress-free screens with exceptional flatness and accuracy.We specialize in producing micro-meshes and filtration components with extremely fine tolerances, capable of machining holes as small as 0.03mm on materials as thin as 0.02mm. Whether you need a small batch for prototyping or a massive volume for mass production, Xinhaisen delivers consistency and speed.

What is Photochemical Etching?

Photochemical etching, also known as chemical milling or photo etching, is a precision manufacturing process used to produce complex metal parts.

Here is a simple breakdown of the process we use at Xinhaisen:

• Cleaning: The raw metal coil is thoroughly cleaned to remove any contaminants.

• Lamination: A light-sensitive photoresist is applied to both sides of the metal sheet.

• Exposure: A photographic tool with the mesh pattern is placed over the metal. UV light is used to harden the photoresist in the shape of the desired mesh (the parts we want to keep).

• Developing: The unhardened photoresist is washed away, leaving the bare metal exposed in the areas that will become the mesh openings.

• Etching: The metal is sprayed with a chemical solution that dissolves the exposed areas, creating the precise mesh openings.

• Stripping: The hardened photoresist is removed, revealing the final, precision etched metal mesh.

This "subtractive" method allows us to create features that are impossible with stamping or laser cutting, all without altering the mechanical properties of the base metal.

Product Features

Choosing Xinhaisen etched meshes means choosing precision and reliability. Our process offers distinct advantages over conventional manufacturing:

• Burr-Free & Stress-Free: Because the process is chemical and not mechanical, there are no burrs, sharp edges, or material deformation. This preserves the flatness and integrity of the metal.

• Ultra-High Precision: We achieve micro-hole diameters down to 0.03mm and line widths as fine as 0.015mm with exceptional uniformity.

• Material Versatility: We etch a wide variety of metals to suit your specific environment, including Stainless Steel (304, 316L), Copper, Brass, Nickel, and specialty alloys.

• Thin to Thick Capabilities: Our expertise covers a wide thickness range, from ultra-thin foils (0.02mm) to thicker structural components (1.5mm).

• Design Flexibility: Hole shapes are not limited to circles. We can etch squares, slots, hexagons, and custom logos without expensive hard tooling changes.

• Scalability: Our production process is highly scalable. We can handle urgent, high-volume orders with rapid turnaround times.

Product Specifications

Our standard manufacturing envelope allows for a wide range of customization. Below are our general capabilities:

Note: Custom specifications outside these ranges can be discussed with our engineering team.

Applications

The versatility of our etched meshes makes them essential parts across a diverse range of industries. Xinhaisen products are found in:

• Acoustics & Audio: Speaker grilles, receiver meshes, microphone covers, and sound-damping screens for mobile phones and headphones.

• Automotive: Fuel injection filters, airbag inflator filters, gaskets, and EMI shielding for sensors.

• Medical: Surgical instrument components, precision filters for diagnostic equipment, and implantable device screens.

• Electronics: Battery electrode grids, mask stencils, EMI/RFI shielding, and cooling vents.

• Industrial Filtration: Hydraulic oil filters, high-flow strainers, filter discs, and sifting screens for food processing.

• Aerospace: Lightweight ventilation panels, precision filters for fuel systems.

• Home Appliances: Anti-insect screens for ventilation, filter meshes for coffee machines, juicers, and vacuum cleaners.

Why Choose Xinhaisen Etched Meshes?

• Unmatched Precision: With the ability to produce 0.03mm micro-holes and maintain tight tolerances, we solve filtration and acoustic challenges that other manufacturers cannot.

• Rapid Turnaround: Our in-house tooling and streamlined etching lines allow us to respond quickly to urgent and large-volume orders.

• Superior Quality: We maintain strict quality control over raw material procurement and every step of the production process to ensure consistency.

• Industry Experience: We have a proven track record in the communications, acoustics, and automotive sectors, understanding the technical demands of modern manufacturing.

Frequently Asked Questions (FAQ)

Q1: What is the difference between woven mesh and etched mesh?
A: Woven mesh is made by interlacing wires, which can shift under pressure. Etched mesh is manufactured from a solid sheet of metal, creating a rigid, single-piece structure with perfectly uniform holes that will not distort.

Q2: Can you etch shapes other than round holes?
A: Yes. One of the major advantages of photo etching is design flexibility. We can etch squares, rectangles, slots, hexagons, custom logos, or any 2D shape required for your application.

Q3: What is the minimum order quantity (MOQ) for custom meshes?
A: We cater to both prototyping and mass production. While we are capable of high-volume runs, we welcome clients with small-batch, custom requirements.

Q4: How long does it take to get a prototype?
A: Tooling for photo etching is relatively fast. Typically, once drawings are approved, prototype tooling and samples can be produced within 1-2 weeks.

Q5: Does XinSen offer non-standard materials?
A: Absolutely. We specialize in various metal etching. If you have a specific material requirement (such as Molybdenum or Inconel), please contact us with your specifications.

Q6: Are the edges sharp? Do they need secondary deburring?
A: No. Because the metal is dissolved away chemically, etched edges are smooth and burr-free. No secondary deburring operations are required, saving time and cost.

Welcome to contact us at any time!