Exploring the Etching Process in Detail: A Step-by-Step Guide

In today’s advanced manufacturing landscape, chemical etching—also known as photo etching—stands out as a highly precise, cost-effective, and scalable method for producing complex metal components. From aerospace to electronics, this method delivers burr-free, stress-free, and high-precision results with exceptional repeatability.

In this article, we provide a step-by-step etching process guide that explains how raw materials are transformed into intricate metal parts through the power of chemistry and photolithography.

Step 1: Material Selection

The process starts with selecting the appropriate metal sheet. Common materials include:

• Stainless Steel (SS304, SS316, SUS301, etc.)

• Copper and Copper Alloys

• Nickel, Titanium, Aluminum

• Custom Alloys (on request)

Material thickness typically ranges from 0.02mm to 3.0mm, depending on the application.

Step 2: Cleaning & Preparation

Metal sheets are thoroughly cleaned in a cleanroom environment to remove oils, oxidation, and contaminants. A clean surface ensures accurate adhesion of photoresist layers during the next step.

Step 3: Photoresist Coating

A light-sensitive photoresist film is laminated onto the metal sheet. This layer will define the areas to be etched and those to remain protected.

Step 4: Exposure

Using high-resolution phototools (masks), the coated sheet is exposed to UV light. This transfers the design pattern onto the metal, hardening the areas exposed to light while leaving others soluble.

Step 5: Developing

The unexposed photoresist is removed using a mild developer, revealing the bare metal in areas that need to be etched. This step finalizes the mask for the chemical process.

Step 6: Chemical Etching

The sheet is passed through an etching machine that sprays a ferric chloride or cupric chloride solution onto the exposed areas. The metal is dissolved precisely without altering its mechanical properties.

Key benefits:

• No burrs

• No mechanical stress

• Extremely fine detail achievable

Step 7: Stripping

The remaining photoresist is stripped away, and the sheet is cleaned, leaving behind the finished etched pattern.

Step 8: Quality Inspection

Final products undergo dimensional and visual inspection, including 2D vision systems, thickness measurements, and microscope checks to ensure every part meets customer specifications.

Applications of Photo Etched Parts

Etched components are widely used in:

• Bipolar plates for fuel cells

• Filter meshes and screens

• Speaker grilles and nameplates

• RFI/EMI shielding

• Encoder discs, shims, and washers

Why Choose Xinhaisen for Your Etching Needs?

With over 10 years of experience, a 7000㎡ modern facility, and a dedicated cleanroom, Xinhaisen Technology delivers world-class etching services trusted by global clients in aerospace, automotive, medical, and electronics industries.

Need high-precision etched metal parts?
Contact our team today for custom solutions tailored to your exact needs.