When you need to remove material or change the surface textures, two common processes are chemical etching and sandblasting. Chemical etching utilizes acids or other chemicals to burn away material in a controlled way. Sandblasting employs particles that are propelled at high velocities to blast away surface material. Both processes can work well, but are suited for different purposes. Deciding between chemical etching vs sandblasting ultimately depends on what you would like to achieve, your budget, and the materials you are working on. We will compare both processes to help you decide.
What is Chemical Etching?
Chemical etching can dissolve materials using liquid chemicals in a controlled manner. This method utilizes liquid acids or alkali solutions to catalytically create precise patterns and shapes. It is conducted at room temperature, meaning it takes longer than generally comparable mechanical methods. The results of a chemical etch are smooth, burr-free edges that mechanical processes cannot provide.
How it Works
Chemical etching uses a process of steps that demand particular preparation and timing.
You start by cleaning the material to remove grease, dirt, and oxidation. Next, you apply a protective coating called photoresist over the entire material. Then you expose the coated material to UV light through a pattern or mask. The light changes the resist properties in the properly exposed areas. The chemical solution only attacks the unprotected metal areas of your material. The photoresist protects the remaining material and creates the desired pattern. The temperature and timing will allow you to control how deep the etching is.
TMNetch Etching Services
TMNetch is a photochemical etching company utilizing state-of-the-art technology and committed to providing rapid turnaround. They have stock materials in their warehouse for etching from 0.01mm to 2.0mm thickness and are always ready to etch.
- Prototype production within 6 hours
- Production within 3 days
- 4 fully automatic etching lines that are 20 meters long each
- 24-hour customer service support online
- Complete control of the process from design to final component
- Export documentation and shipping included
Parts from TMNetch include everything in the envelope from your design file to your completed parts, with international shipping and customs paperwork capabilities.
TMNetch engages with customers in various industries, especially electronics, medical devices, and automotive components, just to name a few. Visit TMNetch to review capabilities and request quotes for your chemical etching needs.
Understanding Sandblasting
Sandblasting propels abrasive particles at high velocity with compressed air or water to a surface. The impact will:
- remove material
- clean surfaces,Â
- or displace a specific amount of material to create a textured finish.
All sandblasting methods remove material by means of physical impact and can treat large surfaces very quickly. The result is a rough, textured surface with good coating adhesion characteristics.
Chemical Etching vs Sandblasting: What’s the Difference?
There is a paramount difference between chemical etching vs sandblasting. Chemical etching uses chemical reactions to dissolve the material. Sandblasting uses a particle emitted at a high frequency to physically knock the material away.
Precision
- Chemical Etching: Very precise patterning with tight tolerancing. Chemical etching is suitable for details this small, down to 0.025mm. If you need intricate designs or complex shapes, chemical etching is the most suitable method. Edge quality is smooth and burr-free.
- Sandblasting: Sandblasting will always produce less precise patterning due to the particles removing the material randomly. This method is better used for general surface preparation and for large areas. Little control over how you remove the material (exact amount).
Surface Finish
- Chemical Etching: Chemical etching is capable of producing smooth, even surfaces without a change in texture, and keeping original surface properties for untreated areas. Chemical etching produces clean cuts and sharp transitions between etched and unetched areas.
- Sandblasting: Due to the use of particles to remove material, sandblasting will always produce a textured, rough surface. The nature of the surface roughness will vary depending on the type of media used and the pressure settings. Sandblasting cannot produce the same type of smooth finishes as chemical methods.
Equipment
- Chemical Etching: Will require tanks, a heating source, and ventilation equipment. Initial costs of setting up chemical etching remain quite low. Once established, maintenance and operational procedures are fairly simple. Chemical etching is suitable for small work areas.
- Sandblasting: Will require compressors, blast cabinets, and dust collection systems. The area required to operate the equipment and the power required to operate are greater. Operating and maintaining the equipment is not as easy.
Safety Issues
- Chemical Etching: Hazardous, possible burns and fumes inhaled, requires ventilation and protective clothing, waste disposal requires special handling.
- Sandblasting: Dust clouds are possible; lungs are damaged. High noise levels will damage hearing. Flying particles can result in injury to the skin and eyes; they require an enclosed cabinet and breathing apparatus.
Cost
- Chemical etching: In chemical etching vs sandblasting cost, equipment costs are lower for chemical etching. Disposal of chemicals contributes to the ongoing costs of operation. Labor costs are fairly moderate since etching can be processed in batches.
- Sandblasting: Equipment set-up and costs are higher. The cost of labor-intensive work also adds up.Â
Chemical Etching vs Sandblasting: Choosing the Right Method
Your decision to use chemical etching vs sandblasting will depend on several important factors that suit your specific project needs. Take these factors into consideration:
- Required accuracy
- Surface finish requirement
- Materials compatibility
- Production volume requirements
- Budget requirements
- Safety and environmental concerns
Chemical etching is the preferred choice for accurate patterns, smooth finishes, or detailed work on metals. In electronics, medical devices, and decorative applications, chemical etching is the clear choice.
Sandblasting is your choice when you need a fast removal of materials, surface preparation, or texture finishes. Sandblasting works great for cleaning, paint removal, and creating uniform textured surfaces on large areas.
FAQs About Chemical Etching vs Sandblasting
What is the best material for sandblasting?
Aluminum oxide is the most suitable medium for most applications. It cuts quickly, lasts long, has consistent results with different materials, and types of surface.
Does etching increase surface roughness?
Chemical etching is able to maintain smooth surfaces, and sandblasting will always make a surface rougher. Chemical etching and sandblasting will have opposing effects on surface texture and finish quality.
What is the difference between acid etch and sandblasted glass?
Acid etching produces smooth, even, frosted surfaces, while sandblasted glass displays a rough, textured finish. Acid etching yields better quality detail and is thinner and more consistent than sandblasting.
Chemical etching vs sandblasting: Which is better?
Neither is better than the other in all respects. Chemical etching is superior for detailed work, and sandblasting excels in rapid material removal and surface preparation tasks.
Conclusion
Both chemical etching vs sandblasting fulfill vital roles in manufacturing and surface treatment. For detailed projects, chemical etching is your best option, as it offers precision and fine finishes. Sandblasting, on the other hand, will usually offer quick material removal or surface preparation of additional areas for larger-scale projects. Knowing the chemical etching vs sandblasting differences helps you to understand the best process for your project.
Do you need precise chemical etching services? TMNetch can provide rapid prototypes and quality results because of the fast and precise automated equipment. The TMNEtch team is experienced in working on complex projects.