Photochemically Etched Shims
Precision-etched shims are critical components used across aerospace, medical devices, automotive, electronics, and industrial manufacturing to fill gaps, align components, compensate for tolerances, and reduce vibration between mechanical assemblies. Fotofab offers superior quality and accuracy for the production of thin-metal shims.
Our digital photochemical etching technology ensures high accuracy, minimal material waste, and cost-effectiveness, making it an ideal choice for producing these essential components. From simple spacer shims to complex geometries with intricate features, Fotofab delivers burr-free, tightly tolerance parts that maintain the structural integrity and performance characteristics of the base material.
Why Photochemical Etching for Shims?
Traditional manufacturing methods like stamping, laser cutting, and CNC machining introduce limitations that can compromise shim performance. Stamping creates burrs and mechanical stress. Laser cutting generates heat-affected zones that alter material properties and leave slag. Stamping require expensive hard tooling that makes design changes costly and add long lead times.
Fotofab’s photochemical etching process solves these challenges. We use chemical etchants to selectively remove material without heat or mechanical force, producing flat, burr-free shims that preserve the original properties of the metal. Because no hard dies are used, you can iterate prototypes without waiting for new tools, then scale seamlessly to full production with consistent quality.
Applications Across Critical Industries
Our precision-etched shims solve alignment, spacing, and tolerance compensation challenges in sectors where performance and reliability are non-negotiable.
Aerospace and Defense
Maintain precise tolerances in landing gear systems, engine mounts, structural joints, and avionics assemblies with AS9100D and ITAR certified materials like stainless steel, titanium, and Inconel for extreme environments.
Medical Devices
Achieve exceptional precision and biocompatibility in surgical instruments, diagnostic imaging equipment, and implantable devices with 316L stainless steel and titanium that meet stringent tolerances for life-critical applications.
Automotive and Electric Vehicles
Ensure proper alignment and vibration reduction in engine assemblies, transmissions, battery packs, and power electronics with copper and brass for thermal/electrical conductivity or stainless steel for high-temperature durability.
Electronics and Microelectronics
Maintain spacing and improve performance in circuit boards, connectors, EMI/RFI shielding, and thermal management systems with materials as thin as 0.001″ (0.025mm) and accuracy to ±10% of metal thickness.
Industrial Machinery
Absorb accumulated tolerances and reduce wear in pumps, compressors, gearboxes, and heavy equipment with custom shims in any configuration from simple washers to complex shapes with slots, holes, and custom features.
Renewable Energy Systems
Ensure reliable operation in wind turbines, solar panel mounting systems, and hydropower equipment with corrosion-resistant shims that maintain alignment in outdoor environments and compensate for thermal expansion in high-temperature solar applications.
Metals Commonly Used in Photochemical Etching for Precision Shims
Fotofab employs a variety of metals in the photochemical etching process to ensure precision, durability, and accuracy.
Typical metals used for shims include:
Other alloys are available for specific project needs.
Value-Added Services for Complete Solutions
Beyond etching, Fotofab offers integrated capabilities that reduce your supply chain complexity:
- Plating: Nickel, tin, silver, and gold plating options to improve corrosion resistance, wear characteristics, or conductivity for specific applications.
- Forming and bending: Press brake forming for angled or multi-level shim configurations when flat parts won’t meet assembly requirements.
- Finishing: Passivation, deburring, and cleaning services to meet cleanliness standards for medical and aerospace applications.
- Custom Packaging: Kitting, labeling, and packaging solutions to simplify inventory management and assembly operations.
Benefits of Photochemical Etching for Busbars with Fotofab
High-precision components that enhance performance and efficiency
Our proven photochemical etching process delivers the tight tolerances and burr-free edges required for precision shim applications, eliminating expensive tooling costs while maintaining stress-free material integrity across all production volumes.
Benefits of this process include:
Burr-Free Edges: Produce smooth, clean edges with no burrs or sharp protrusions that could interfere with mating components.
Stress-Free Production: Maintain original mechanical properties without work hardening, warping, or residual stress from heat or mechanical force.
Design Flexibility: Change designs quickly and affordably with low-cost digital tooling rather than expensive hard dies.
Rapid Prototyping: Move from concept to prototype in days, then scale directly to production with consistent quality.
Complex Geometries: Add holes, slots, notches, and custom shapes at no additional cost regardless of design complexity.
Tight Tolerances: Achieve ±10% of metal thickness standard, with tighter tolerances available for critical applications.
Material Versatility: Etch from stainless steel, titanium, copper, aluminum, brass, and specialty alloys from 0.001″ to 0.060″ thick.
Consistent Quality: Deliver repeatable accuracy batch after batch with full traceability through ISO 9001:2015 certification.
Fotofab Advantages
Blending experience, expertise, and the latest advanced technologies, Fotofab has positioned itself as a leader in advanced photochemical etching solutions for shims and other components, ensuring high precision, cost-effectiveness, and rapid production times.
Delivering higher precision and faster production, we’ve become the trusted partner for precision components used across a range of leading industries.
Adhering to strict quality control standards and certifications, we ensure each product meets or exceeds industry benchmarks for performance and reliability. Our proven process generates less waste and requires fewer resources, minimizing our environmental impact.
Fotofab is committed to quality.
