Chemical Etching Formula
Zn1 Pure Zinc
with HCl(15%)+H₂SO₄(5%)
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 HCl(15%)+H₂SO₄(5%) for Zn1 Pure Zinc?
The HCl(15%)+H₂SO₄(5%) formula is selected for Zn1 Pure Zinc because it balances oxidation rate, surface chemistry, and bath stability for this alloy class. Chemistries that etch too aggressively create excessive undercut and rough sidewalls; chemistries that are too mild require impractically long dwell times or attack the photoresist. HCl(15%)+H₂SO₄(5%) sits in the productive middle for Zn1 Pure Zinc, which is why it appears in this reference set.
Process Window & Bath Control
The process window for this HCl(15%)+H₂SO₄(5%) formula centres on 28°C and as specified. Conveyor speed spans 0.2-3.94 m/min over the 0.05-0.5 mm thickness band; the typical operating point is 0.65 m/min. Every 5°C drop in bath temperature requires roughly a 30% reduction in conveyor speed to hold the same etch depth, so temperature stability is the single biggest lever on consistency.
Design Rules & Tolerances
Feature sizes scale with sheet thickness. For this formula the minimum hole diameter ranges 60-600 μm and the minimum line width ranges 100-500 μm across the 0.05-0.5 mm band, following the industry 1.2× (hole) and 1.0× (line) thickness rules. Single-side undercut ranges 9-89 μm, and the etch factor is about 2.80. Size your photomask by subtracting twice the expected undercut from each finished feature dimension.
• Minimum hole diameter range: 60-600 μm
• Minimum line width range: 100-500 μm
• Single-side undercut range: 9-89 μm
• Typical etch factor (EF): 2.80
Yield & Production Economics
This formula delivers a typical yield of 98.1% (range 97.5-98.4%). At that rate, per-part economics are driven mostly by fixed photomask and setup cost for small batches and by sheet utilisation for large runs. The chemistry itself does not change with quantity, so the same recipe serves prototype and production volumes.
Typical Applications
Zn1 Pure Zinc etched with this recipe typically ends up in decorative trim and low-cost precision flat parts. Because chemical etching applies no mechanical or thermal load, the finished features are free of work-hardening and heat-affected zones — a decisive advantage over stamping or laser cutting for these uses.
More Zinc Alloys Formulas
Other formulas in the same material family.
Frequently Asked Questions
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.