Ultra-Thin Etched Stainless Steel & Copper Encoder Discs with Burr-Free Edges for German market

Ultra-Thin Etched Stainless Steel & Copper Encoder Discs with Burr-Free Edges for German market

What is Etching?
Metal etching is a precise, subtractive manufacturing process that uses controlled chemical solutions to remove material, creating intricate and burr-free patterns on thin metal without inducing stress or heat deformation. It is ideal for producing high-tolerance, flat components with fine, complex geometries.

Encoder Discs Overview
Our chemically etched encoder discs are critical parts for optical and magnetic rotary encoders, used to translate rotational position into digital signals. They feature exceptionally precise radial patterns (lines, slots, or windows) that ensure accurate, reliable, and repeatable motion feedback in high-speed systems.

Manufacturing Process

1. Material Preparation: Selection and cleaning of ultra-flat metal substrates.

2. Photoresist Lamination: Application of a uniform light-sensitive layer.

3. Photolithography: High-precision UV exposure transfers the master disc pattern from digital tooling onto the resist.

4. Developing: Removal of exposed/unexposed resist to reveal the pattern.

5. Etching: Precise chemical etching forms the absolute pattern with vertical sidewalls.

6. Stripping & Cleaning: Removal of residual resist and thorough cleaning.

7. Metrology & Inspection: High-magnification optical inspection and critical dimension measurement.

Encoder Discs Features

• Ultra-High Precision: Achieves extremely fine line widths and tight angular/radial tolerances for accurate signal generation.

• Burr-Free & Zero Stress: No mechanical contact ensures smooth edges and no part warping, maintaining perfect flatness and signal integrity.

• Complex Pattern Flexibility: Easily produce intricate radial codes, custom index marks, multi-track designs, and unique sector patterns without costly hard tooling.

• Rapid Prototyping: Digital tooling allows for fast design iterations and immediate production of functional prototypes.

• Material Versatility: Available in various metals including stainless steel (for durability), brass, and specialty alloys.

Encoder Discs Specifications

Encoder Discs Applications

• Industrial Automation: Servo motors, CNC machines, robotic arms.

• Medical Devices: Imaging equipment, pumps, surgical robotics.

• Aerospace & Defense: Gyroscopes, actuators, navigation systems.

• Optical & Scientific Instruments: Precision stages, telescopes, spectrometers.

• Consumer Electronics: High-end printers, scanners, cameras.

Our Advantages

• Precision Specialists: We excel at producing defect-free, high-line-count discs with absolute accuracy, critical for encoder performance.

• Speed to Market: No hard tooling required. Fast turnaround from design to prototype to full production.

• Unmatched Consistency: Photochemical process ensures every disc in a batch is identical, ensuring reliable system performance.

• Integrated Quality Control: Rigorous in-process inspection at every stage guarantees disc quality.

• Proven Partner: Trusted supplier for demanding industries where motion control precision is non-negotiable.

Why Choose Xinhaisen?
For encoder discs where accuracy defines performance, choose Xinhsen. We transform your precise design into a flawless, functional component. Our etching technology provides the ideal combination of micron-level precision, design freedom, and manufacturing agility, enabling you to innovate faster and build more reliable motion control systems.

Welcome to contact us at any time!