Chemical Etching Formula
1J85 Super-Permalloy with FeCl₃+HCl

Formula Summary

The table below summarizes every parameter that defines this etching formula. Values listed as ranges scale with sheet thickness across the supported band.

Why FeCl₃+HCl for 1J85 Super-Permalloy?

Ferric-chloride-based formulas are the industrial workhorse for ferrous, nickel, and copper-bearing alloys like 1J85 Super-Permalloy. The Fe³⁺ ion oxidizes the metal surface; where HCl is present it regenerates dissolved species and stabilizes chloride concentration. The result on 1J85 Super-Permalloy is anisotropic etching with predictable undercut and an easily regenerated spent bath.

Process Window & Bath Control

Hold the bath at 50°C with concentration 44 °Bé (specific gravity 1.410). Across the 0.05-0.3 mm thickness range, conveyor speed runs from 0.19-2.77 m/min — thinner sheets move faster, thicker sheets slower, in roughly inverse proportion to thickness. A typical mid-range setpoint is 0.67 m/min for 0.15 mm stock. Use redundant PID temperature control to hold the bath within ±1.5°C, and titrate at least once per shift.

Design Rules & Tolerances

Design rules for this recipe: hole diameter 60-360 μm, line width 100-300 μm, single-side undercut 9-54 μm — all as a function of thickness across 0.05-0.3 mm. The higher the etch factor (this formula holds about 2.77), the tighter the achievable tolerance. Below the minimum feature sizes, yield falls off steeply, so treat those numbers as hard floors rather than targets.

Yield & Production Economics

Expect a yield in the 96.1-96.8% range for 1J85 Super-Permalloy with FeCl₃+HCl, with 96.6% typical on a well-controlled line. Most rejects trace back to upstream coating and exposure rather than to the etch bath itself, so tightening photolithography control is usually the fastest path to a higher number.

Typical Applications

Typical applications for 1J85 Super-Permalloy processed with FeCl₃+HCl include hermetic sealing rings, lead frames matched to glass/ceramic, and magnetic shielding. The formula's tolerance band and yield make it well suited to medium-to-high-volume precision flat parts.

Process Equipment & Material Reference

Process equipment for the 1J85 Super-Permalloy / FeCl₃+HCl combination is built around our biomedical blade etching machine platform — closed-loop temperature control, redundant pump headers, and metering for bath replenishment all directly affect the etch factor and yield numbers cited on this page.

The material above is documented on this page at the recipe level. Bath chemistry, temperature, and conveyor speed are the controlling variables for repeatable output.

Production Use Cases for This Formula

Across the markets we serve, the FeCl₃+HCl formula on this page is most often deployed for tea-infuser custom filter etching, juicer filtration mesh etching, and stainless steel metal filter mesh. These applications share thin-feature geometries that benefit from the predictable etch factor near 2.77 and the low single-side undercut documented above.

If your part falls into one of these classes — or a closely adjacent one — this formula is usually the right starting point. We confirm fit with a short sample run on the actual sheet stock before locking in mask artwork.

Other Metals Etched with FeCl₃+HCl

The FeCl₃+HCl chemistry is also documented for these alloys.

More Precision Alloys Formulas

Other formulas in the same material family.

Frequently Asked Questions