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Photochemical Machining Process Guide

Photochemical machining (PCM), also known as photochemical milling or photo etching, is a chemical milling process that uses photoresist and etchants to machine away selected areas of sheet metal components. The process starts by printing the shape of the part onto photographic film, which is used to create a photoresist template on the metal sheet. The sheet is then etched away in the unprotected areas, producing a precision part accurately and economically. PCM can be used for thin, complex metal parts across various industries like electronics, automotive, and more.

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659 views9 pages

Photochemical Machining Process Guide

Photochemical machining (PCM), also known as photochemical milling or photo etching, is a chemical milling process that uses photoresist and etchants to machine away selected areas of sheet metal components. The process starts by printing the shape of the part onto photographic film, which is used to create a photoresist template on the metal sheet. The sheet is then etched away in the unprotected areas, producing a precision part accurately and economically. PCM can be used for thin, complex metal parts across various industries like electronics, automotive, and more.

Uploaded by

KAMALJEET SINGH
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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PHOTO CHEMICAL

MACHINING
Photo Chemical Machining
• Photochemical machining (PCM), also known
as photochemical milling or photo etching
• It is a chemical milling process used to fabricate sheet metal
components using a photoresist and etchants to corrosively 
machine away selected areas.
• This process emerged in the 1960s as an offshoot of the printed
circuit board industry.
• Photo etching can produce highly complex parts with very fine
detail accurately and economically.
 Photochemical machining is a form of photo engraving, and a
similar process in microfabrication is called photolithography.
Process
• The process starts by printing the shape of the part onto optically
clear and dimensionally stable photographic film.
• The "photo tool" consists of two sheets of this film showing negative
images of the parts (meaning that the area that will become the parts
is clear and all of the areas to be etched are black).
• The two sheets are optically and mechanically registered to form the
top and bottom halves of the tool.
Process
• The metal sheets are cut to size, cleaned and then laminated on both
sides with a UV-sensitive photoresist.
• The coated metal is placed between the two sheets of the photo tool
• Vacuum is drawn to ensure intimate contact between the photo tool
and the metal plate.
• The plate is then exposed in UV light that allows the areas of resist
that are in the clear sections of the film to be hardened.
• After exposure, the plate is "developed", washing away the
unexposed resist and leaving the areas to be etched unprotected.
Etching and cleaning
• The etching line is a multi-chambered machine that has driven-wheel
conveyors to move the plates and arrays of spray nozzles above and
below the plates.
• The etchant is typically an aqueous solution of acid, frequently 
ferric chloride, that is heated and directed under pressure to both
sides of the plate.
• The etchant reacts with the unprotected metal essentially corroding it
away fairly quickly.
• After neutralizing and rinsing, the remaining resist is removed and the
sheet of parts is cleaned and dried.
Advantages
• This process can offer economical alternatives to stamping,  punching
, laser or water jet cutting, or wire electrical discharge machining
 (EDM) for thin gauge precision parts.
• The tooling is inexpensive and quickly produced. This makes the
process useful for prototyping and allows for easy changes in 
mass production.
• It maintains dimensional tolerances and does not create burrs or sharp
edges.
• It can make a part in hours after receiving the drawing.
Applications
• PCM can be used on virtually any commercially available metal or alloy, of any
hardness.
• It is limited to materials with a thickness of 0.0005 to 0.080 in (0.013 to
2.032 mm).
• Metals include aluminum, brass, copper, Inconel, manganese, nickel, silver,  steel
, stainless steel, zinc and titanium.
• Industrial applications include fine screens and meshes, apertures and masks,
battery grids, fuel cell components, sensors, springs, pressure membranes, 
heat sinks, flexible heating elements, RF and microwave circuits and components,
semiconductor lead frames, motor and transformer laminations, metal gaskets
 and seals, shields and retainers, electrical contacts, encoders and light choppers,
EMI/RFI shields, jewelry and washers.

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