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Cost-effective process delivers burr and stress free metal parts
Original equipment manufactures (OEMs), designers and engineers can now benefit from the many advantages associated with the production of metal components using the most refined photo-chemical machining (PCM) technology.
The process is refined to the highest levels by industry-leading specialist, Tecan, delivering cost-effective burr and stress free custom metal parts. Low tooling costs and rapid turnround are particularly beneficial elements of the well-proven PCM process. Complex designs are as easy to tool as straight-forward requirements and in all cases tooling modifications are also low cost. The technology lends itself to the fast and efficient production of prototypes and allows for down-the-line design iterations to be incorporated with minimal delay.
Established applications include products such as semiconductor leadframes, optical encoder discs, washers, shims, gaskets, meshes, deposition masks and RFI screening cans. The process can produce etched fold lines for ease of subsequent 3D forming without tools and allows different metals to be processed with the same tooling. Parts may be supplied independently or tagged to sheets for ease of handling, counting, storage and transportation. Also, company logos, part numbers and idents of all kinds can easily be etched into the surface during manufacture at no extra cost. Most metals, from 0.01mm to 1.5mm thick, may be used and the process does not affect magnetic or other material properties.
Using Computer Aided Design (CAD) tooling is generally produced from customers' own drawings and specifications. Customers may also supply their own designs via post, modem or the Internet. Most software protocol can be interpreted. Files are transferred to a photo plotter, where the image is accurately reproduced onto film and a 'Photomaster' produced. This Photomaster can be quickly and cost effectively replaced if modifications are required.
Parts are produced from a pre-cleaned metal 'blank' which is coated with a light-sensitive photoresist and exposed to ultra violet light, which hardens the resist. Unexposed areas are developed away, leaving bare metal which is sprayed with etching solution on both sides, at high pressure. This accurately removes the unwanted metal and the resist is removed to leave behind burr and stress free components.
The company's R & D department is geared to solving the most challenging PCM projects and welcomes joint-development initiatives to produce optimised parts as cost-effectively as possible. QA systems include non-destructive X-ray fluorescent testing and rigorous inspection on all components and the provision, on request, of a Certificate of Conformance or Release Note. Detailed records are maintained and kept on all jobs, ensuring traceability.
Established applications include products such as semiconductor leadframes, optical encoder discs, washers, shims, gaskets, meshes, deposition masks and RFI screening cans. The process can produce etched fold lines for ease of subsequent 3D forming without tools and allows different metals to be processed with the same tooling. Parts may be supplied independently or tagged to sheets for ease of handling, counting, storage and transportation. Also, company logos, part numbers and idents of all kinds can easily be etched into the surface during manufacture at no extra cost. Most metals, from 0.01mm to 1.5mm thick, may be used and the process does not affect magnetic or other material properties.
Using Computer Aided Design (CAD) tooling is generally produced from customers' own drawings and specifications. Customers may also supply their own designs via post, modem or the Internet. Most software protocol can be interpreted. Files are transferred to a photo plotter, where the image is accurately reproduced onto film and a 'Photomaster' produced. This Photomaster can be quickly and cost effectively replaced if modifications are required.
Parts are produced from a pre-cleaned metal 'blank' which is coated with a light-sensitive photoresist and exposed to ultra violet light, which hardens the resist. Unexposed areas are developed away, leaving bare metal which is sprayed with etching solution on both sides, at high pressure. This accurately removes the unwanted metal and the resist is removed to leave behind burr and stress free components.
The company's R & D department is geared to solving the most challenging PCM projects and welcomes joint-development initiatives to produce optimised parts as cost-effectively as possible. QA systems include non-destructive X-ray fluorescent testing and rigorous inspection on all components and the provision, on request, of a Certificate of Conformance or Release Note. Detailed records are maintained and kept on all jobs, ensuring traceability.
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