Acid Etching
Fotofab’s high-precision, computer-aided photochemical acid etching delivers intricate, burr-free metal components with unmatched accuracy, ideal for both industrial applications and decorative designs.
Our powerful non-contact process allows for tight tolerances, complex geometries, and rapid prototyping without the stress, distortion, or tooling costs of traditional machining methods.
What is acid etching, and how does it differ from PCE?
Acid etching is a general term for chemical processes that remove metal using acidic solutions to shape parts or surfaces. Photochemical etching (PCE) is a highly controlled subset of acid etching that uses photoresist masks and UV exposure to achieve precise, repeatable patterns for industrial-grade components.
During the acid etching process, a strong chemical solution – typically ferric chloride – is applied to a metal surface such as brass, steel or copper, where it dissolves the exposed areas not protected by a mask. This enables the creation of highly detailed components or decorative designs tailored precisely to project specifications.
At Fotofab, we specialize in high-precision, computer-aided photochemical acid etching designed for industrial-grade performance and repeatability across functional and aesthetic applications. This non-contact process does not cause thermal or mechanical stress, enabling burr-free edges, complex geometries and high detail and precision without the need for expensive tooling.
Learn more about our precision photochemical etching services.
Benefits of Computer-Aided Photochemical Acid Etching with Fotofab
Computer-aided photochemical acid etching delivers more precise metal parts with tighter tolerances than metal stamping, laser cutting, and CNC machining. And the benefits don’t stop there:
Efficiency
Chemical etching typically takes less than a day, often less than an hour, to complete. This means your custom, brand-new parts are ready to ship the same day.
Standard lead times are 5-7 days from the order date, with an optional expedited service available.
Cost Effectiveness
No expensive tools are used in chemical etching, greatly reducing the cost, time and effort to produce custom parts.
Efficiency
Unlike some other manufacturing methods, acid etching does not alter the internal structure, grain structure, or ductility of the metal. The material’s mechanical properties remain unchanged before and after the etching process.
Burr-free
Acid-etched parts are guaranteed to be free from burrs and mechanical stress, which can interfere with part function. This eliminates the need for costly secondary deburring operations that may be necessary with other manufacturing processes.
Our Proven Etching Process
Leveraging the latest, industry-leading technology, our computer-aided, photochemical acid etching process begins with meticulously cleaning the metal sheet, followed by applying a photoresist mask that defines the desired pattern.
The masked material is then exposed to UV light in a computer-aided process to harden the image area. Theunprotected sections are etched away using our proprietary etching chemistry, engineered for precise, repeatable results. The remaining photoresist is then stripped, leaving behind clean, burr-free components.
This advanced, non-contact process, combined with state-of-the-art technology, delivers high-precision metal parts with complex geometries and tight tolerances, all while avoiding the stresses, tooling costs, and design limitations of traditional machining.
The Metals We Chemically Etch
Here at Fotofab, we provide computer-aided photochemical acid etching services for a wide range of metals, including:
Aluminum
Aluminum is used for both industrial and non-industrial applications, but it can be difficult to choose the right grade for your project.
Available alloys
- 1100
- 2024
- 3003
- 5052
- 6061
1100, 2024, 3003, 5052, 6061
Beryllium Copper
Used where electrical conductivity, mechanical strength and non-magnetic properties are needed. Common uses are EMI/RFI shields, contacts and connectors and precision springs.
Brass
Chemical etching brass is a highly effective method for producing durable designs capable of withstanding harsh indoor and outdoor environments. By leveraging the unique properties of brass, such as its corrosion resistance and malleability, chemical etching ensures that the resulting designs maintain their integrity and aesthetic appeal over time. This makes it an ideal choice for a wide range of applications from decorative and architectural work to precision metal manufacturing where detail and tolerances are critical.
Copper
Fotofab is a leader in the precision chemical etching of copper, offering components across a diverse range of industries. Our proven process ensures exceptional electrical and thermal conductivity, essential for high-performance applications.
Available alloys
- Beryllium Copper: C172, C192
- Brass: C260
- Copper: C110, C101
- Nickel Silver: C715, C770
- Phosphor Bronze: C510, C521
Applications of Acid Etched Parts
Fotofab’s precision etched parts are responsible for powering some of the world’s leading industries. Some of the key applications include:
Aerospace Components: Aircraft relay parts, engine components, and radar jamming devices
Biomedical Devices: Prosthetics, surgical instruments, and implantable components
Decorative: jewelry, architectural designs, nameplates and other decorative and aesthetic uses.
Electrical Contacts & Connectors: High-precision electrical contacts, pins, terminals, and interconnects
EMI/RFI shielding: Custom shields for mitigating electromagnetic and radiofrequency interference on PCBs
Formed Metal Enclosures: For miniature or hybrid electronic circuit protection and structure
Industrial Equipment: Precision flexure springs, metal meshes, screens, filters, and gaskets
Pre-etching: Clean or micro-texture surfaces, improving adhesion for coatings, paints or bonding agents.
Renewable Energy Systems: Fuel cell plates and electrolyzer components for clean energy applicationsLead Frames: For supporting semiconductor devices and ensuring secure electrical connections
Lead Frames: For supporting semiconductor devices and ensuring secure electrical connections
Value Added Services for Chemically Etched Parts
Fotofab offers an array of value-added and finishing options to guarantee your project gets closer to the production finish line. While chemical etching is our core business, we have an extensive list of resources to give you a ready-to-use component, no matter what your requirements, including:
- Forming
- Plating
- Passivation
- Diffusion Bonding
- Electropolishing
- Custom Packaging
- Anodizing
- Blackening
- Stamping
- Laser Cutting & More
Why Choose Fotofab for Acid Etching?
Fotofab is a trusted partner for precision computer-aided photochemical acid etching due to our unwavering commitment to precision, quality, and responsiveness. With over five decades of experience, we deliver high-precision metal components ranging from simple to highly complex geometries, whether you need a rapid-turn prototype or a full-scale production run.
Our team is known for its expert customer support, fast turnaround times, and deep understanding of technical requirements. We’re AS9100D and ISO 9001 certified, ITAR registered, and RoHS compliant, giving customers confidence in our ability to meet the rigorous industry standards across the world’s leading industries.