Custom Etched Optical Encoder Disc & Rotary Encoder Wheel for Motion Sensing

Custom Etched Optical Encoder Disc & Rotary Encoder Wheel for Motion Sensing

Product Overview

Xinhaisen specializes in the high-volume production of precision metal encoder discs (also known as code wheels or optical encoders). Using advanced photochemical etching, we produce intricate, burr-free patterns with tight tolerances. These discs are critical for converting mechanical motion into electrical signals in high-precision systems.

What is Etching?

Etching (photochemical machining) is a subtractive manufacturing process. A metal sheet is coated with photosensitive resist, exposed to a precise digital pattern, developed, and then chemically dissolved to create complex features. Unlike stamping or laser cutting, etching creates no burrs, no heat-affected zones, and no mechanical stress, making it ideal for thin, delicate encoder discs.

Product Features

• High Precision: Achieves positional accuracy of up to ±0.01mm (customizable).

• Fine Lines & Gaps: Minimum line width / space down to 0.02mm (20µm).

• Burr-Free & Stress-Free: Smooth edges ensure clean optical readings; no deformation.

• Material Versatility: Available in SUS301, SUS304, beryllium copper, nickel-silver, and other alloys.

• Custom Patterns: Supports incremental, absolute, or custom coded patterns.

• Thickness Range: 0.05mm to 0.4mm (ultra-thin for low inertia).

Product Specifications

Applications

Encoder discs from Xinhaisen are used in industries requiring precise motion control:

• Medical Devices: Surgical robots, motor control systems.

• Aerospace & Automotive: Steering angle sensors, throttle position sensors.

• Industrial Automation: Servo motors, stepper motors, robotic arms.

• Office & Consumer: Printers, scanners, high-end audio volume controls.

• Optical & Measurement: Optical encoders, tachometers.

Why Choose Xinhaisen?

• Rapid Prototyping: No hard tooling required; low NRE cost for custom designs.

• Scalability: From 10 pcs to 10 million pcs with consistent quality.

• Superior Quality: All discs pass strict flatness and optical inspection.

• Cost-Effective for Complex Parts: High-complexity patterns cost no more than simple ones.

• Fast Turnaround: Short lead times for urgent OEM/ODM orders.

FAQ

• Q1: What is the thinnest encoder disc you can make?
  A: We can etch encoder discs as thin as 0.05mm for ultra-low inertia applications.
• Q2: Can you produce a disc with a custom code pattern (non-standard slots)?
  A: Yes. We work from any 2D CAD or Gerber file. Custom patterns are our specialty with no extra tooling cost for prototypes.
• Q3: How does etching compare to laser cutting for encoder discs?
  A: Etching is superior for thin metals because it produces no heat burrs, no recast layer, and higher throughput for batch production. Laser may cause micro-burrs that affect optical performance.
• Q4: What is your typical lead time for a custom encoder disc?
  A: Prototypes: 5–7 working days. Mass production: 7–15 working days after approval.
• Q5: Do you offer surface finishing or post-processing?
  A: Yes. We provide deburring, cleaning, passivation, and flattening as needed.
• Q6: What quality standards do you follow?
  A: We follow ISO 9001:2015 quality management with 100% optical inspection for critical dimensions.

Welcome to contact us at any time!