CapabilitiesMetallization of CeramicsResistive Coating
of Ceramics
Brazed Assembly ServicesPhotochemical MachiningCeramic Glazing ServicesElectro and Electroless
Plating Services
Precision Machining
Services
PortfoliosVideosSpecial Process - Selective PlatingPhotochemically Milled 3D Traveling Wave Tube GridsPhotochemicaly Etched
Custom Nitinol Parts
Photochemicaly Etched
Custom Moly-Copper Parts
Etched Soft Magnetic
Cobalt-Iron Alloys

 

Certifications:
  RoHS
  

Photochemical Machining

Chemically Milled Flat 1
[Click on thumbnail to enlarge]Chemically Milled Flat 2
[Click on thumbnail to enlarge]Chemically Milled Grids
[Click on thumbnail to enlarge]
We have over four decades of experience in manufacturing photochemically etched components for the military and aerospace markets. Optical encoders, lead frame prototypes, and R/F shielding components are some of the common photochemically machined products that we manufacture. Elcon specializes in processing diverse base materials, including molybdenum, tungsten, copper, stainless steel, and titanium, with thicknesses ranging from 0.0005" to 0.100".

Technical designs for your projects are created by our CAD/CAM department. Using Optibeam printers, photographic artwork designed from custom specifications are plotted on to photoresists that preserve surface metal during photo etching. After the imaging phase, we use Chemcut etchers to remove undesired areas from metal surfaces. Our photochemical etching process offers several advantages, including low cost tooling, design flexibility, fast turnaround, and dimensional repeatability.

Flat as well as 3D curved surfaces can be precisely etched to tight tolerances of up to 0.00025". Through chemical milling, we accurately etch holes and slots on a wide range of materials. The minimum hole diameter and spacing between holes can be 1.5 times the material thickness. Our average lead time is 3 weeks ARM for planar and 8 weeks ARM for 3D Grids. Expediting services are also available.

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Specifications

Photochemical Machining Process
(See Process Description Below)
3D Photoetching
Step Etching
Half Etching
Alternative Naming Conventions for
Photochemical Machining
Chemical Milling
Chemical Machining
Photo Milling
Photochemical Milling
Photo Etching
Photochemical Etching
Additional Design CapabilitiesCAD Design
CAM Programming
Materials (Metals) Molybdenum
Tungsten
Tungsten-Copper
Hastoly
Copper-Molybdenum
Hafnium
Amzirc
Copper
Alloy Steels
Alloy 42
Alloy 46
Gold
Beryllium
Brass
Phosphorous Bronze
Iron
Inconel
Nickel
Palladium
Stainless Steel
Titanium
Nitinol
Palco
Characteristics/BenefitsLow Cost
Fast Turnaround
Design Flexibility
Dimensional Repeatability
Photochemical Etching and Chemical Machining EquipmentChemcut Etchers
Optibeam Printers
Industry FocusDepartment of Defense
Department of Energy
Solar Product Manufacturing
Aerospace
Biomedical
Communications
Computer and Electronics
Vacuum Electronics
Medical
Military
Semiconductor
Optical
Intended Applications for Photochemical Machined ProductsFiber Optics
R/F shielding
Optical Encoders
Lead Frame Prototype
Aerospace Components
Traveling Wave Tube Shadow and Control Grids (TWT)
Vacuum Electronics
Microwave Transmitting Tubes
Medical Components
Minimum Material Thickness0.0005 inches (in)
0.0012 centimeters (cm)
0.0127 millimeters (mm)
Maximum Material Thickness0.100 inches (in)
0.002 centimeters (cm)
0.025 millimeters (mm)
Minimum Hole Diameter1.5 x Material Thickness
Minimum Space between features1.5 x Material Thickness
Minimum 3D Photo Etching on a curve surfaceMinimum 3D Photo Etching on a curve surface
c over r 66%
Min Diameter=0.07 inches
Min Thickness=0.002 inches
Maximum 3D Photo Etching on a curve surfaceMaximum 3D Photo Etching on a curve surface
c over r 66%
Max Diameter=18 inches
Max Thickness=0.007 inches
Maximum Sheet Length2 feet (ft)
24 inches (in)
0.61 meters (m)
60.69 centimeters (cm)
609.60 millimeters (mm)
Maximum Sheet Width1.66 feet (ft)
20 inches (in)
.508 meters (m)
50.8 centimeters (cm)
508 millimeters (mm)
Typical Sheet Sizes12 x 12 Inches
12 x 18 Inches
9 x 12 inches
6 x 12 inches
Tolerance 24 x 20 flat sheet+0.005 inch
-0.005 inch
Tolerance 6 x 6 flat sheet+0.00025 inch
-0.00025 inch
Tolerance for a curve surface
( @ .07" Diameter )
+0.0005 inch
-0.0005 inch
Tolerance for a curve surface
(@ 18" Diameter )
+0.002 inch
-0.002 inch
Production VolumePrototype
Production High Volume
Testing CapabilitiesPlating Functional Testing
XRF to Check Thickness
SPC and PFMEA
Typical Lead Times Available3 Weeks ARM For Planar and 8 Weeks ARM For 3D Grids
Expediting Services Available
Secondary Services OfferedPlating (Gold, Nickel, Silver, and Copper)
Forming
Machining
Brazing
Desired File FormatsAutoCAD (DWG, DXF)
Mechanical Desktop (DWG)
Inventor ( IAM, IPT, IDW)
SAT
STEP
IGES
SolidWorks (SLDASM, SLDDRW, SLDPRT)
StandardsISO 9001:2008
AS 9100
MIL-G-45204 (Gold Plating)
AMS-QQ-N-290 (Nickel Plating)
QQ-S-365D (Silver Plating)
MIL-C-14550B (Copper Plating)
Location1009 Timothy Drive, San Jose, CA 95133 USA
Photochemical MachiningIs a process of using photoresist to preserve the surface of metal, while using an etchant to dissolve away selected areas.

Portfolio

Special Process – Selective PlatingPhotochemically Milled 3D Traveling Wave Tube Grids  Manganese

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