Copper is one of the earliest metals used by humans. As early as prehistoric times, people began mining open-pit copper mines and using the obtained copper to make weapons, jewelry, and various utensils. The use of copper has profoundly influenced the progress of early human civilization. Due to its good ductility, high thermal conductivity, and electrical conductivity, it is widely used in electrical, light industry, machinery manufacturing, construction, aerospace, and defense fields.
In TMN’s more than ten years of custom metal parts service, copper is also one of the most used metal materials. So why choose copper etching to manufacture your parts? Compared to other processes, what advantages does the copper etching process have?
Comparison of Copper Etching with Traditional Processing Techniques:
Using photo etching to process copper and copper alloy materials has several main advantages over traditional processing techniques, such as stamping, laser cutting, and others:
1. High Precision and Complex Patterns:
Photo etching can achieve extremely high precision and detail, producing very complex patterns and shapes. This characteristic is especially important for manufacturing microelectronic components, precision filters, and complex circuits.
2. Stress-Free Processing:
Traditional mechanical processing methods (such as stamping and cutting) generate mechanical stress and deformation in the material. Photo etching, however, is a contactless process that does not apply physical pressure, thus avoiding stress and deformation issues.
3. Burr-Free and No Heat-Affected Zone:
Unlike mechanical or laser cutting, photo etching does not produce burrs. The cut edges are smooth and do not require subsequent processing. Additionally, photo etching does not create a heat-affected zone, preventing thermal deformation or damage to the material.
4. High Material Utilization:
Copper etching allows precise control of the etched area, minimizing waste of copper material and maximizing utilization. This is particularly important for both copper and copper alloy materials.
5. Strong Mass Production Capability:
The photo etching process is very suitable for mass production, allowing simultaneous processing of copper materials, greatly improving production efficiency and reducing production cycles.
6. High Flexibility:
If design issues are discovered after receiving copper part samples, you can quickly modify the drawings without needing to replace molds or reprogram machines. Modifications are cost-free and faster.
If you want your copper parts to have higher precision, be stress-free, and have efficient production, photo etching becomes an ideal choice.
Note: Learn more about the photochemical etching process
Precision Parts Manufactured by Copper Etching:
At the beginning of the article, we mentioned that copper is one of the earliest metals used by humans, with a long history. After years of development, it has been widely used in electronic products, Decorative Arts, construction, aerospace, and defense industries. So, what parts can photo etching provide in these fields? TMN will introduce the most commonly processed metal parts below:
Vapor Chambers:
First, the main function of Vapor Chambers is to quickly dissipate heat to ensure the stable operation of equipment. The better the thermal conductivity, the better the cooling effect. Secondly, they need to be corrosion-resistant during long-term use to maintain their structural and functional integrity. Thirdly, since they are mainly used in portable electronic products such as mobile phones, tablets, and laptops, they should be as light and thin as possible without affecting thermal conductivity to reduce the weight of these electronic products.
Copper has a high thermal conductivity, about 400W/m·K, allowing it to rapidly conduct heat, making it the ideal material for heat sinks. It also has good corrosion resistance, remaining stable in various environments. Furthermore, copper is easy to form and process, allowing complex heat sink structures to be manufactured through various processes (such as photo etching and stamping). So why choose photo etching among these many processes?
The most important reason is that photo etching maximizes the preservation of copper’s properties because the process does not generate mechanical stress or thermal stress, which do not affect the copper material. Additionally, the process involves directly printing the design pattern on the copper sheet and etching away the excess material, allowing even the most complex designs to be easily manufactured. These are the reasons why many people choose photo etching for processing Vapor Chambers.
Note: Learn more about TMN’s vapor chamber process
Lead Frames
Lead frames need to possess the following main characteristics: excellent electrical and thermal conductivity, high strength and durability, good processability, and precise dimensional stability. Electrical and thermal conductivity ensure efficient transmission of electrical signals and heat. High strength and durability ensure the reliability of the lead frames during long-term use. Good processability and dimensional stability allow them to fit accurately with various packaging and assembly processes.
These requirements make copper widely used in the manufacture of lead frames. Apart from its thermal conductivity, corrosion resistance, and ease of processing, copper also has excellent electrical conductivity, perfectly meeting the requirements of lead frames. The reasons for choosing photo etching to manufacture lead frames are similar to those for other copper components. The manufacturing of lead frames requires high precision and complex geometric shapes while preserving the material’s properties to the greatest extent.
Note: Learn more about TMN’s lead frame process
Nameplates, Door Plates, Decorative Art
Nameplates, door plates, and decorative art products require a good appearance to enhance visual effects and brand image while maintaining clean details and text during long-term display and use in various environments. Therefore, the material needs to have a beautiful and high-end appearance, durability, and weather resistance to adapt to different environmental conditions.
Copper is one of the most commonly used metals for manufacturing nameplates, door plates, and decorative art. Choosing photo etching allows for stress-free processing, high-precision pattern and text processing, and the creation of very fine and complex designs, enhancing the product’s appearance and detail. It also allows for quick design and pattern changes, making it suitable for personalized and diverse needs, as well as large-scale production, significantly reducing manufacturing costs and improving production efficiency.
Note: Learn more about TMN’s “Nameplates, Door Plates, Decorative Art” process
3D Model Puzzles
3D model puzzles need to have high precision and detail clarity, be easy to assemble and disassemble, and possess durability and stability, as well as a beautiful appearance. High precision and detail clarity ensure that puzzle components can fit accurately, durability and stability ensure that the puzzle is not easily damaged during multiple assemblies and disassemblies, and a beautiful appearance enhances the overall aesthetic value.
Copper has a unique luster and texture, making 3D model puzzles look more high-end and exquisite. Copper is also strong and durable, not easily damaged, allowing the puzzle to withstand multiple assemblies and disassemblies while remaining intact. Its good plasticity makes it easy to create more delicate 3D model puzzles. Like the previous products, choosing photo etching to manufacture 3D model puzzles allows for high precision and rich detail. This process also allows precise control of material removal, producing more puzzle components from a single material and reducing material waste.
Note: Learn more about TMN’s 3D Model Puzzles process
Conclusion
The above content detailed why you should choose copper etching to manufacture your parts. Whether it’s for high-precision, high-complexity Vapor Chambers, lead frames requiring high conductivity and durability, or nameplates, door plates, and decorative artworks emphasizing appearance and detail, the photo etching process offers unique advantages. For 3D model puzzles, photo etching not only achieves high precision and rich detail but also maximizes material utilization and reduces production costs.
By using the photo etching process, we can maintain the original properties of copper materials while avoiding the impacts of mechanical stress and thermal stress during manufacturing, ensuring the quality and performance of parts. These advantages make the photo etching process an ideal choice for manufacturing copper parts in various fields.
If you need to customize high-precision, complex structure, and stress-free copper parts, the photo etching process is undoubtedly your best choice. TMN is committed to providing professional custom metal parts services and looks forward to exploring more applications and innovations in copper etching processes with you.
Note: Learn more about TMN>>>
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