Chemical Etching Technical Guidelines

Designing for chemical etching

Below is an overview of the technical considerations for designing precision metal components for chemical etching. For a more detailed understanding, download our technical guideline document below.

Download technical guidelines

Suitable materials, thicknesses & sheet sizes

We stock over 2,000 material types in a wide range of sheets sizes, thicknesses and grades. We also supply specialist materials on request.

See a full list of materials

METAL TYPE	THICKNESS RANGE	MAXIMUM SHEET SIZE
Steel and stainless steels	0.01mm – 2.5mm	600mm x 1500mm
Nickel and nickel alloys	0.01mm – 1.5mm	600mm x 1500mm
Copper and copper alloys	0.01mm – 1.5mm	600mm x 1500mm
Aluminium	0.01mm – 1.5mm	600mm x 1500mm

Standard etching tolerances

MATERIAL THICKNESS	MINIMUM TOLERANCE	TECHNICAL TOLERANCE	MINIMUM HOLE/SLOT	MINIMUM LAND AREA
0.01mm – 0.1mm	±0.025mm	Contact us	0.1mm	0.050mm
0.1mm – 0.25mm	±0.025mm	Contact us	100% metal thickness	75% metal thickness
0.25mm – 2.5mm	±10% metal thickness	Contact us	100% metal thickness	75% metal thickness

Corner radii

With photo etching, the smallest inside and outside corner radius achievable is directly proportional to the thickness of the selected metal being processed.

A - Outside corner radius – minimum of 75% material thickness
B - Inside corner radius – minimum of 100% material thickness

Hole & Profile Geometries

During etching, the etchant attacks the material laterally and vertically resulting in an edge “cusp” which is typically 10 to 20% of material thickness.

Precision Micro can control the etch cusp, allowing for a range of profiles. This gives products unique characteristics, such as sharp cutting edges or conical openings.

1 Single-sided etch

Used to achieve a specific depth, profile or for thin gauge metals

2 Convex profile

Industry standard edge condition for through-etched components

3 Parallel profile

Used to reduce etch cusp

4 70/30 etch

Combines through etching and depth etching and can also be used to produce conical apertures or cutting edges

5 Double-sided depth etch

Used for surface engraving on both sides

6 Concave etch

Used to achieve a straighter edge profile

7 2/3 stage etch

Used to achieve multiple depths, requiring additional imaging

Component tags

Tags are small threads of metal used in the etching process to secure components within the sheet. They become essential when precise etch tolerances are needed or when components need subsequent electroplating or assembly.

Precision Micro provides various etch tags to choose from, depending on the components shape, thickness or intended use.

Following manufacturing, components can either be delivered with tags intact within the sheet or as separate individual parts. Depending on the required size, design or tolerance specifications, we can also produce components without etch tags.