Zinc Alloys HCl(15%)+H₂SO₄(5%)

Chemical Etching Formula
Zamak3 Zinc Alloy with HCl(15%)+H₂SO₄(5%)

For engineers selecting an etching chemistry for Zamak3 Zinc Alloy, the HCl(15%)+H₂SO₄(5%) formula shown here defines the bath composition, temperature window, and achievable feature sizes across a 0.1-0.3 mm thickness band. Typical mass-production yield for this recipe is 97.6%, with a typical conveyor speed of 0.59 m/min at 28°C.

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.

HCl(15%)+H₂SO₄(5%) Etchant System
— °Bé Concentration
1.080 Specific Gravity
28 °C Bath Temperature
Through etch (double-sided) Etch Depth Type
0.1-0.3 mm Thickness Range
0.20 mm Typical Thickness
0.35-1.45 m/min Conveyor Speed Range
0.59 m/min Typical Speed
120-360 μm Min Hole Ø Range
100-300 μm Min Line Width Range
18-55 μm Undercut Range
2.72 Etch Factor (EF)
97.6% Typical Yield (97.4-97.8%)

Why HCl(15%)+H₂SO₄(5%) for Zamak3 Zinc Alloy?

HCl(15%)+H₂SO₄(5%) earns its place as a Zamak3 Zinc Alloy etching formula through repeatability. The bath can be titrated and corrected each shift to hold concentration (as specified) and specific gravity (1.080) within a tight band, which keeps the etch factor near 2.72 and yield near 97.6% run after run.

Process Window & Bath Control

Hold the bath at 28°C with concentration as specified (specific gravity 1.080). Across the 0.1-0.3 mm thickness range, conveyor speed runs from 0.35-1.45 m/min — thinner sheets move faster, thicker sheets slower, in roughly inverse proportion to thickness. A typical mid-range setpoint is 0.59 m/min for 0.20 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

When laying out artwork for Zamak3 Zinc Alloy at through etch (double-sided), plan for a minimum hole diameter in the 120-360 μm range and a minimum line width in the 100-300 μm range, depending on the chosen sheet thickness within 0.1-0.3 mm. The etch factor of ~2.72 and undercut range of 18-55 μm determine how much the mask must be biased to land the finished dimension on target.

Design Rule Summary
• Minimum hole diameter range: 120-360 μm
• Minimum line width range: 100-300 μm
• Single-side undercut range: 18-55 μm
• Typical etch factor (EF): 2.72

Yield & Production Economics

Expect a yield in the 97.4-97.8% range for Zamak3 Zinc Alloy with HCl(15%)+H₂SO₄(5%), with 97.6% 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

Parts produced with the HCl(15%)+H₂SO₄(5%) formula on Zamak3 Zinc Alloy are common in decorative trim and low-cost precision flat parts. The burr-free, stress-free nature of chemical etching makes it the preferred process wherever flatness and edge quality matter more than raw throughput.

More Zinc Alloys Formulas

Other formulas in the same material family.

Zn1 Pure Zinc HCl(15%)+H₂SO₄(5%) Through etch (double-sided)

Frequently Asked Questions

Single-side undercut ranges 18-55 μm depending on thickness and dwell time. When sizing the photomask for a finished feature on Zamak3 Zinc Alloy, subtract twice the expected undercut from the target width so the etched dimension lands on specification.

Need a Quote for This Process?

WET Etched runs production wet chemical etching lines using the HCl(15%)+H₂SO₄(5%) chemistry. Send us your part drawing and quantity for a full process quote.

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