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Formed Photo Etched Parts Design Guide
Forming and Special Processes for Manufacturing Precision Parts
Tech-Etch manufactures formed parts by combining photo etching or photo chemical milling, used for blanking, with inexpensive or universal tooling, used for forming. This method produces burr-free parts in intricate and complex designs and shapes. It also makes it possible to prove your design in preproduction quantities without having to commit to expensive, progressive die tooling. The following guidelines represent practical methods to assure proper function and the best cost.
Prove your design in preproduction quantities.
Burr-free parts in intricate and complex shapes.
1/2-depth etching for hand forming on applications like board level shielding.
Heat treatment for enhanced spring qualities.
For a quotation, please send a sketch, formal drawing or cad file of your part and the approximate quantity required. You can also use our form to contact us.
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HAND FORMING
For bends that do not require structural strength and where a sharp internal radius is desired, such as board-level shielding applications, depth etched bend lines may be used for hand forming. The lines are produced by etching a groove along the bend line of the part. By eliminating the need for forming tools, the cost is lowered.
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BEND RADII
In the forming process, care is taken to design the proper bend radii, since larger radii can withstand a larger deflection without failure. Example B is designed to take a larger deflection than Example A.
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| HEAT TREATMENT
Tech-Etch can heat-treat many materials, including Beryllium Copper, to achieve close dimensional control. Heat treatment enhances spring qualities by permitting greater deflection without compression set and without increasing the material's stiffness.
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TOLERANCES
Preferred forming tolerances are as shown.
(Consult factory if tighter tolerances are desired.)
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MINIMUM BEND RADIUS
Temper selected for a given bend radius depends on material thickness and the position of the bend with respect to grain direction.
This table below shows suggested minimum bend radii.
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| MATERIAL |
ALLOY |
TEMPER |
MINIMUM RADIUS FORMABILITY 90° |
| GRAIN DIRECTION |
| ACROSS |
45° |
WITH |
| BeCu |
C172 |
A |
SB |
SB |
SB |
| BeCu |
C172 |
1/4 H |
SB |
SB |
SB |
| BeCu |
C172 |
1/2 H |
0.5 x T |
0.7 x T |
1.1 x T |
| BeCu |
C172 |
H |
1.0 x T |
2.0 x T |
2.2 x T |
| BRASS |
C260 |
A |
SB |
SB |
SB |
| BRASS |
C260 |
1/2 H |
SB |
SB |
SB |
| BRASS |
C260 |
H |
0.7 x T |
1.3 x T |
1.6 x T |
| BRASS |
C260 |
S |
1.0 x T |
1.8 x T |
3.7 x T |
| STAINLESS STEEL |
301/302 |
1/4 H |
1.0 x T |
1.0 x T |
1.0 x T |
| STAINLESS STEEL |
301/302 |
1/2H |
1.0 x T |
2.0 x T |
2.0 x T |
| STAINLESS STEEL |
301/302 |
H |
2.0 x T |
4.0 x T |
4.0 x T |
Consult factory if tighter radius is desired.
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ASSEMBLY
Tech-Etch's precision spot welding equipment is used to join small parts as well as accurately close cylinders and boxes. Soldering is an alternative. Various adhesives are also applied to join assembled components as well as offer customers a method of attachment. Staked or welded studs and contacts can also be applied.
FINISHING
Tech-Etch has a full in-house plating and mechanical finishing facility. This includes Gold, Nickel, Electroless Nickel, Copper, Tin, and Tin-lead plating, plus solder hot oil reflow. Electropolishing, surface polishing, and vibratory tumbling are part of the finishing department. Tech-Etch's masking skills can be used for selective plating.
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