Tag Archives: Stainless Steel Etching

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Methods and Costs of Stainless Steel Processing for High-Precision Applications

Explore the various methods for stainless steel processing, including laser cutting, CNC machining, chemical etching, stamping, and electropolishing. Learn the costs, advantages, and suitability for high-precision applications like stainless steel coffee filter nets.

SUS316 Stainless Steel Filter Mesh

Table of contents

Case study:SUS 316 Stainless Steel Coffee filter

200,000 pcs delivery quantity as an example.
Overall 3.5 inch diameter, 0.2 mm thickness, 0.05 mm mesh aperture.

Stainless Steel Processing Methods and Costs

In industries that require precision, the processing of stainless steel is a critical aspect of production. Stainless steel is widely used in applications that demand high corrosion resistance, strength, and durability. This article explores several common methods of SUS 316 stainless steel processing, analyzing each method’s advantages, disadvantages, and costs, with a specific focus on producing SUS 316 stainless steel coffee filter nets.

1. Laser Cutting

Equipment Costs:

  • The cost of laser cutting machines can range from $100,000 to $500,000, depending on the machine’s precision, power, and automation level. For high-precision applications, such as cutting stainless steel coffee filter nets with small mesh sizes (0.05mm holes), a more advanced machine is required, which can drive the price towards the upper end of the range.
  • Additional Costs: Post-processing equipment, such as deburring and cleaning systems, can add another $10,000 to $50,000 to the overall investment.

Production Costs:

  • Laser cutting is an efficient method for high-volume production but can result in thermal deformation, especially with thin stainless steel (e.g., 0.2mm thick). This can affect the flatness of the material, requiring additional steps to maintain quality.
  • Maintenance Costs: Regular maintenance for high-end laser cutting machines typically costs around $5,000 to $10,000 per year.

Suitability:

  • Laser cutting is well-suited for intricate designs and precise cuts. However, due to the thermal impact on thin stainless steel, it may not be ideal for applications requiring perfect flatness, such as precision mesh filter production.

Recommended Manufacturer:

2. CNC Machining

Equipment Costs:

  • CNC machines range from $150,000 to $600,000, depending on the complexity, precision, and automation features. For applications like stainless steel filter net production, where high precision is essential, the equipment costs tend to be on the higher end.
  • Tooling and Fixtures: Custom fixtures may be required to handle thin stainless steel, which could add another $20,000 to $50,000 to the total cost.

Production Costs:

  • CNC machining is excellent for precision and complex designs, but it is slower than laser cutting. This results in higher per-unit costs when producing large volumes (such as 200,000 units).
  • The process may also induce material deformation due to the clamping pressure on thin sheets of stainless steel, leading to potential flatness issues.
  • Maintenance Costs: High-precision CNC machines typically incur annual maintenance costs of around $10,000 to $20,000.

Suitability:

  • CNC machining is ideal for intricate, custom designs with tight tolerances. However, due to slower processing speeds, it is not the most cost-effective option for high-volume production of stainless steel filter nets.

Recommended Manufacturer:

3. Chemical Etching

Equipment Costs:

  • Chemical etching systems are generally much more affordable, with equipment costs ranging from $50,000 to $150,000. The primary investment is in etching tanks, chemical handling systems, and automated control systems.
  • Additional Costs: Support equipment, such as wash tanks and drying systems, can add another $10,000 to $30,000.

Production Costs:

  • Chemical etching is perfect for high-precision, high-volume production, especially for thin materials like stainless steel. The process is cold, which means there are no thermal effects on the material, ensuring that the flatness of the stainless steel remains intact.
  • Maintenance Costs: The annual maintenance costs for chemical etching systems are relatively low, ranging from $3,000 to $5,000 per year for chemicals and system upkeep.

Suitability:

  • Chemical etching is ideal for producing fine mesh designs (like the 0.05mm holes in stainless steel coffee filter nets). It is a fast, efficient process that maintains material integrity and precision, making it an excellent choice for large-scale production.

Recommended Manufacturer:

4. Mechanical Stamping

Equipment Costs:

  • Stamping presses are typically priced between $100,000 and $500,000, depending on the machine’s tonnage and features. For high-precision stamping of stainless steel filter nets, additional investment in tooling and dies is often required.
  • Die Costs: Custom dies for mesh patterns may cost between $10,000 and $30,000.

Production Costs:

  • Mechanical stamping is a high-speed process, making it ideal for mass production. However, for thin stainless steel (like 0.2mm), stamping can cause material deformation, affecting the flatness and precision of the filter net.
  • Maintenance Costs: Stamping equipment requires relatively low maintenance, with annual costs typically around $2,000 to $5,000.

Suitability:

  • While stamping is excellent for large runs of simple designs, it is less suited for producing precise, fine mesh patterns due to its potential for material deformation.

Recommended Manufacturer:

5. Electropolishing

Equipment Costs:

  • Electropolishing equipment is relatively affordable compared to other methods, with system costs ranging from $30,000 to $100,000, depending on size and automation features.
  • Additional Costs: Equipment for handling the electrochemical process and supporting systems like polishing tanks can add $5,000 to $20,000.

Production Costs:

  • Electropolishing is primarily used as a surface finishing process. It does not impact the mesh geometry or hole sizes but significantly improves the surface quality of stainless steel, enhancing its corrosion resistance and appearance.
  • Maintenance Costs: Maintenance and chemical replenishment typically cost $5,000 to $10,000 per year.

Suitability:

  • Electropolishing is best used to improve the surface finish of already-manufactured filter nets, making them more resistant to corrosion and giving them a shiny, smooth appearance. It is not a method for creating mesh designs but an excellent complement to other processes.

Recommended Manufacturer:

Processing technology comparison table

MethodEquipment Costs (USD)Production CostsMaintenance Costs (Annual)Flatness IssuesBest Suited ForRecommended Manufacturer
Laser Cutting$100,000 – $500,000Higher$5,000 – $10,000Thermal deformationPrecision cutting for complex designsTrumpf (trumpf.com)
CNC Machining$150,000 – $600,000Higher$10,000 – $20,000Clamping-induced deformationHigh precision and complex shapesHaas Automation (haascnc.com)
Chemical Etching$50,000 – $150,000Low$3,000 – $5,000NoneHigh-volume, fine mesh productionWET Etched (wetetched.com)
Mechanical Stamping$100,000 – $500,000Low$2,000 – $5,000Deformation from stampingLarge-volume production of simple designsAIDA Engineering (aida.co.jp)
Electropolishing$30,000 – $100,000Low$5,000 – $10,000NoneSurface finishing and corrosion resistance improvementMacDermid Alpha (macdermidalpha.com)

Optimal solution: Chemical etching

For large-scale production of stainless steel coffee filter nets with 0.05mm mesh holes, chemical etching emerges as the most cost-effective and precise method. It ensures material flatness, delivers excellent precision for fine mesh patterns, and is well-suited for high-volume production. Additionally, electropolishing can be used to enhance the surface quality and corrosion resistance of the finished filter nets.

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The Stainless Steel Chemical Etching Process

The stainless steel etching process creates precision components by selectively removing metal through a photoresist mask. This modern technique offers numerous inherent advantages over conventional sheet metalworking, including the ability to produce parts without degrading material properties since no force or heat is used during processing. It also allows for almost limitless part complexity, with component features machined simultaneously using etchant chemistries.

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View or download our Photochemical Metal Etching White Paper How-to Guide

Photo Chemical Metal Etching White Paper Operating GuideDownload

What is Stainless Steel Etching and How Does It Work?

Stainless steel etching is a metalworking process that uses corrosive chemicals to etch complex and precise components from stainless steel. This process is highly favored in modern metal machining due to its high precision and low failure rate.

The stainless steel etching process begins by laminating the metal with a light-sensitive photoresist, which is then exposed to UV light to transfer the CAD image of the component. The unexposed photoresist areas are developed and removed, and the exposed metal is sprayed with etchant chemicals to accurately remove the unprotected stainless steel. Finally, the remaining photoresist is stripped away to reveal the finished etched component.

Wet Metal Etching Production workshop- Shenzhen Xinxin Precision Equipment Co., Ltd.
Stainless Steel Etching Factory Process

Digital Tooling and Economic Efficiency

One of the key advantages of stainless steel etching is its use of digital tooling. Unlike traditional methods that require expensive and difficult-to-adapt steel molds, digital tooling for etching is quick to adapt and change, often within an hour. This ensures that large quantities of products can be reproduced with zero tool wear, guaranteeing that the first and millionth part produced are exactly the same.

The adaptability of digital tooling makes it ideally suited for both prototype and high-volume production runs. This “risk-free” design optimization incurs no financial penalties and boasts a turnaround time that is estimated to be 90% quicker than for stamped parts, which also require substantial upfront investment in mold fabrication.

View the chemical etching stainless steel workflow

Photo Wet Chemical Etching Process

Applications of Etched Stainless Steel Components

The stainless steel etching process is suitable for virtually any metal component between 0.01mm and 1.5mm in thickness. Here are some examples where stainless steel etching truly adds value:

Meshes, Filters, and Sieves: Chemical etching offers greater levels of complexity when producing thin, precision steel meshes, filters, and sieves. Metal is removed simultaneously, allowing multiple aperture geometries to be incorporated without high tool or processing costs. Unlike punch-perforated sheets, photo-etched mesh is burr-free and stress-free, maintaining zero material degradation.

For example, a 150-micron thick precision stainless steel mesh used in radiation detection devices is etched by WET Etched to precision tolerances below the standard ±10% material thickness. The critical honeycomb-shaped mesh array could not be economically produced by stamping due to the high investment required in press tooling, and laser cutting couldn’t achieve the necessary tolerances over such a large surface area.

Flexure Springs and Diaphragms: Often used in safety-critical or extreme environment applications, such as ABS braking systems, medical biosensors, or fuel injection systems, etched flexures can “flex” millions of times faultlessly. Chemical etching ensures that the fatigue strength of the steel is not altered, eliminating potential fracture sites and producing flexures free from burrs and recast layers.

Fuel Cell Bipolar Plates, Cooling Plates, and Fluidic Devices: Stainless steel grades with increased levels of chromium are well-suited for fluidic devices used in liquid-to-liquid or liquid-to-gas heat exchangers, fuel cells, and cooling plates due to their high corrosion resistance. The complex grooves machined into these plates are well-suited to chemical etching, as they can be machined onto both sides in a single process without compromising flatness or introducing stresses and burrs.

Summary

Stainless steel and its various grades possess characteristics that make them ideal for numerous industrial applications. The etching process offers significant advantages for producing complex and safety-critical stainless steel components, including:

  • No expensive hard tooling
  • Rapid transition from prototype to production
  • Almost unlimited part complexity
  • Burr- and stress-free component features
  • Unaffected metal properties
  • Suitability for all grades, with accuracy to ±0.025 mm
  • Lead times measured in days, not weeks or months

The versatility of stainless steel etching, combined with WET Etched’s extensive experience, makes it a compelling option for manufacturing stainless steel components across diverse and demanding applications. This process stimulates innovation, removing obstacles inherent in traditional sheet metalworking technologies.