Chemically-Etched Aluminum Sheets & EMI/RFI shielding

Etched aluminum is frequently used in the aerospace and automotive sectors. Aluminum plates are frequently etched. Electronic components like EMI/RFI shielding, shims, covers, lids, encoder disks, springs, and contacts are made using this method. Air intake grills and heater plates for aircraft can be made from metal. Aluminum dashboard surfaces, instrument dials, and coverings can be machined with various textures, profiles, and even logos for vehicle applications.

Small, printed circuit board components can also be made from etched aluminum parts since a quick, accurate, and reasonably priced technique allows for producing a large number of them at once.

Many businesses prefer aluminum over other materials because of the appealing qualities mentioned above. The aircraft sector, in particular, needs strong, lightweight components that can withstand high temperatures or stresses. Compared to other metals, aluminum has a higher fatigue limit. Heat transfer plates are one example of an aviation component with several lines simultaneously etched during the etching process. As a result, this component can be produced more affordably in large quantities than other processes.

Likewise the automobile sector benefits from aluminum etching with aluminum components like bipolar fuel cell plates that can be produced using a low-cost process. Similar to heat transfer plates, these pieces feature a lot of channels, so the metal etching procedure is more economical. In addition, due to the simultaneous etching of the metal's two surfaces, the procedure also saves time.

Photochemical etching can protect EMI/RFI shielding parts made of aluminum from the magnetic properties of nearby components in any industry that uses electronic systems.

• inventory and brand management
• rapid prototyping
• inherently burr-free parts, which are stress-free and have their physical properties unaltered
• cost-effective production
• high-precision machining

Virtually any metal can undergo acid etching, but metals selected for durability, conductivity, corrosion resistance, or unique surface finishes are typically preferred. Acid etching delivers consistent results on the following metals:

• Titanium – Lightweight and exceptionally strong, titanium is chosen for its biocompatibility, fatigue resistance, and suitability for aerospace and medical applications.
• Aluminum – Known for its strength-to-weight ratio, electrical conductivity, and corrosion resistance, making it popular in electronics, aviation, and automotive etching.
• Copper – Valued for high thermal and electrical conductivity, copper etches rapidly—ideal for manufacturing printed circuit boards (PCBs), EMI/RFI shielding, and electrical contacts.
• Nickel – Offers robust resistance to heat and corrosion; commonly found in alloys for chemical processing and electronics.
• Stainless Steel – Exhibits strong corrosion resistance and durability. While 300 series stainless offers greater corrosion resistance, the 400 series is easier to etch but less resistant to oxidation.
• Bronze – Favored for ductility, stiffness, and resistance to fatigue, bronze is used for decorative, musical, and mechanical components.
• Molybdenum – Provides high strength, superior thermal and electrical conductivity, and a low coefficient of expansion, ideal for high-temperature or space applications.

Metal etching, also known as metal engraving, is the method of producing grooves, fine lines, or detailed patterns on metal parts or sheets. This process serves a wide range of purposes, including decorative, industrial, and architectural applications. Industries that utilize metal etching include jewelry, furniture, architecture, music, art, healthcare, woodworking, aerospace, electronics, and the defense sector. For example, manufacturers may use decorative etching to darken surfaces, making etched lines more prominent. Additionally, metal etching allows parts to meet strict weight requirements by removing a thin layer through chemical or mechanical processes

What is a standard metal etching process?

Cleaning Surfaces

The process begins with surface cleaning to prepare the metal for etching. It is essential to remove all contaminants, as they can interfere with the etching reaction and cause uneven results. Solvents, including de-oxidizing and alkaline solutions, are commonly used to clean the metal. Typical contaminants are grease, primer, marking residues, and oils.

Applying Masking Agent

In industrial applications, maskants such as isobutylene-isoprene copolymers and neoprene elastomers are applied because they resist chemical reactions. The masking material is patterned onto the surface to outline the desired design, either by dipping or flow coating. In dip masking, parts are submerged in maskant, while flow coating applies the maskant over the surface.

Immersion in Etchant

At this stage, the actual metal etching occurs. The masked metal parts are immersed in a chemical solution, such as ferric chloride, for a specific period to achieve the required width and depth. Several factors influence the outcome, as previously described.

Removing the Mask

In the final step, known as demasking, both the reaction by-products and maskant are removed to reveal the finished pattern. Cold water or specialized de-oxidizing baths are used to eliminate chemical residues. Various methods, often manual scraping, are used to remove the maskant from the part.

Need some help? Looking for a quote? We’re always happy to hear from new or existing customers!

Just Email us Susan@xinhsen.com.