Frequently Asked Questions

Process

What are the chemicals used in photoetching?

Various chemicals are used depending on the material that is being etched. Common etchants include ferric chloride and hydrofluoric solutions.

Does photo etching alter the properties of the metal?

No. Unlike traditional machining (such as stamping or laser cutting) there is not stress or extreme heat applied to the metal which could potentially affect the metal properties.

What are the design considerations when photo etching?

There are some basic minimum hole/slot sizes, minimum inside radii and other material considerations outlined in our "Design Guide to Photochemical Machining".

What are some advantages of using the chemical etching process?

Low-cost tooling, quick turnaround time, and flexibility in part design.

What are the benefits of dropout versus tabbed parts?

Drop out parts will not have a burr when the part is detached from the sheet, however, it is etched less consistently, so the tolerances are greater

What are tabs?

Typically, parts are laid out on a sheet of metal (usually 12" X 18" sheet) in a step and repeat fashion. Depending on the size of your part and metal thickness, a number of tabs will be placed to hold your part into the metal sheet. Removing the tabs can be easily completed by hand. For more on Tabs, visit our Tabs Page.

Is the Fotofab process a burr-free process?

Yes, technically. There are no burrs created when the part is made (such as the case with traditional metal stamping). However, Fotofab uses tabs to keep your part attached to the sheet of metal so we can keep tight tolerances during the etching process. We can choose to not use tabs and have your part drop out of the sheet, but tolerances may increase and some yield loss may occur. If you are unsure if your part is best produced as a "tabbed" or "drop out", please contact one of our sales staff. If you are unsure if your part is best produced as a "tabbed" or "drop out", please contact one of our sales staff.

Why does the quote mention small burrs or tabs when parts are detached?

The parts are held into the sheets by small tabs. When the parts are detached from the sheet, the place where the part was connected will leave a small burr. To etch metal parts with the best tolerances, we may opt to keep your part tabbed into the sheet.

Can I specify where the tabs should be placed?

Definitely. Please indicate on your drawing where you would like the tabs to appear (or where they cannot appear). Most parts will need 1 to 3 tabs depending on part geometry and metal thickness.

Can you etch tubes or 3D shapes?

At the moment, Fotofab can only etch from 2-D surfaces (such as a metal sheet). We cannot etch on 3D surfaces, and can only form a part after etching is complete.

Can you etch square holes?

There will be an inside radius making the corners not quite 90°, however, the sides of the square can be over-etched a little to allow for a perfect fit with a 90° degree part.

What is a half-etch, or a bend channel?

A half-etch, or a bend channel, is a partially etched area (usually 50-70% depth of the metal thickness) that can be used in hand forming. Typical applications that utilize half-etch features are RF shields.

How long does it take to get parts made?

Standard turnaround time is 10 business days. However, depending on the complexity of the order additional lead time may be necessary. For a premium, we also offer 5-day, 3-day, and same day delivery on most orders.

What types of packaging do you offer?

Parts can be shipped either still in sheets or detached. If the parts are to be detached, the packaging options include: Bulk packing, tubes, boxed in foam layers, pick and place trays, and tape and reel