3. INTRODUCTION
Unprotected metal is chemically dissolved in
photochemical machining. Masks are design
so that components are cut out and
engraved simultaneously. The results are both
decorative and functional.
The chemical cutting is used predominantly to
mill and machine thin sheet metals, is also
known as chemical blanking and
photofabrication.
This process is limited to foils and thin sheet
metal between 0.1mm and 1mm thick.
4. TYPICAL APPLICATION
The technical aspects of this technology
are utilized in aerospace, automotive and
electronics industries.
5. RELATED PROCESS
Laser cutting and engraving are used to
produce similar products.
Abrasive blasting
CNC machining
6. QUALITY
This process produces an edge finish free
from burrs, and it is accurate to within 10%
of the material thickness.
8. DESIGN CONSIDERATIONS
The intricacy of a pattern is restricted by
the thickness of the material: any
configuration can be machined, as long
as the smallest details are large than the
material thickness.
9. COMPATIBLE MATERIALS
Most metals can be photo etched
including stainless stell, mild steel,
aluminium, copper, brass, nickel, tin and
silver.
Glass, mirror, porcelain and ceramic are
also suitable for photo etching.
11. ENVIRONMENT IMPACTS
Metal that is removed from the workpiece
is dissolved in the chemical etchant.
The chemical used to etch the metal is
one-third ferric chloride.
13. INTRODUCTION
This is a high precision CNC process that can
be used to cut, etch, engrave and a mark a
variety of sheet materials including metal,
plastic, wood, textiles, glass, ceramic and
leather.
The two main types of laser used for this
process are CO2 and Nd:YAG.
Both work by focusing thermal energy on a
spot 0.1mm to 1mm wide to melt or vaporize
the material.
14. TYPICAL APPLICATION
Application are diverse and include
modelmaking, furniture, consumer
electronics, fashions, signs and trophies,
point of sale, film and televisions sets, and
exhibition pieces.
15. RELATED PROCESS
CNC maching, water jet cutting and
punching and blanking can all be used to
produce the same effect in certain
materials.
17. DESIGN OPPORTUNITIES
These processes do not stress the
workpiece, like blade cutting, so small
and intricate details can be produced
without reducing strength or distorting the
part.
18. DESIGN CONSIDERATIONS
These are vector-based cutting systems:
the laser follow a series of lines from point
to point.
19. COMPATIBLE MATERIALS
These processes can be used to cut a
multitude of materials including timber,
veneers, paper and card, synthetic
marble, flexible magnets, textiles and
fleeces, rubber and certain glasses and
ceramics.
20. COSTS
There are no tooling costs for this process.
Data is transmitted directly from a CAD
file to the laser cutting machine.
21. ENVIRONMENT IMPACTS
Careful planning will ensure minimal
waste, but it is impossible to avoid offcuts
that are not suitable for reuse.
Thermoplastic scrap, paper and metal
can be recycled, but not directly.
23. INTRODUCTION
High voltage sparks erode the surface of the
workpiece or cut a profile by vaporizing the
material, making this a precise method of
machining metals. Material is removed from
the workpiece and a texture is applied
simultaneously.
Electrical discharge machining (EDM) has
revolutionized toolmaking and metal
prototyping.
There are two versions of the EDM process :
die sink EDM and wire EDM.
24. TYPICAL APPLICATION
EDM equipment is very expensive, so its use
is limited to applications that demand the
very high levels of precision and the ability
to work hardened steels and other metals
that are impractical for CNC machining.
26. QUALITY
The quality of EDM parts is so high they
can be used to manufacture tooling for
injection molding without any finishing
operations.
The quality of the finish and resulting
texture are determined by the cutting
speed and voltage.
27. DESIGN OPPORTUNITIES
EDM produce accurate textures, which
are determined by the machine settings,
eliminating the need for further finishing
operations.
Die sink EDM can be used to produce
internal geometries on parts that are not
possible with conventional machining.
Wire EDM can be used in much the same
way as hot wire cutting polymer foam.
28. DESIGN CONSIDERATIONS
These processes can be produce internal
radii as small as 30 microns.
These do not need to be any larger than
500 microns in most applications.
The thickness of the material that can be
cut by wire EDM ranges from 0.1mm up to
200mm but depends on the capabilities
of the equipment.
29. COMPATIBLE MATERIALS
Metals can be shaped by EDM
techniques.
Metals including stainless steel, tool steel,
aluminium, titanium, brass and cooper are
commonly shaped in this way.
30. COSTS
Low tooling costs for EDM: no tooling costs
for wire EDM: very high equipment costs.
Moderate to high unit costs.
31. ENVIRONMENTAL IMPACTS
This process requires a great deal of
energy to vaporize the metal workpiece.
It does eliminate the need for any further
processing.
The metal electrodes are also suitable for
recycling.
33. INTRODUCTION
Punching refers to cutting an internal
shape.
Blanking is cutting an external shape in a
single operation.
Circular , square and profiled hole can be
cut from sheet.
34. TYPICAL APPICATIONS
Use in :
Automotive and transportation
Consumer electronics and appliances
kitchenware
35. RELATED PROCESSES
This process can only used for thin sheet
matrials up to 5mm.
Related processes
CNC machining
Laser cutting
Water jet cutting
37. DESIGN OPPORTUNITIES
Specialized tooling is required for 3D parts,
which will increase investment cost.
Selective material will reduce weight but
may not reduce strength too much.
38. DESIGN CONSIDERATION
The width of material being removed or
left behind.
Punch diameter or width should be not
smaller than material thickness.
39. COMPATIBLE MATERIALS
Almost all metals can be processed in this
way.
Commonly used to cut carbon
steel,stainless steel and aluminium and
copper alloys.
40. COST
Low to moderate tooling cost
Low to moderate unit costs
41. ENVIRONMENTAL IMPACTS
Any scrap is collected and separated for
recycling, so there is very little wasted
material.
47. DESIGN OPPORTUNITIES
A multitude of materials can be die cut.
Means that an entire packaging system
can be shaped in this way.
48. DESIGN CONSIDERATIONS
The type of material will determine the
thickness that can be cut
Nesting parts is essential to reduce cycle
time , scrap material and cost in general
49. COMPATABLE MATERIALS
Many materials can be cut by die casting
, including plastic sheet, plastic film,
cardboard, board, foam, rubber, leather,
textile, very thin matels, flexible magnets
and cork.
53. INTRODUCTION
A high-pressure jet of water, which is
typically mixed with abrasive, produce
the cutting action.
This is a versatile process for cold cutting
sheet materials.
57. DESIGN OPPORTUNITIES
This process cuts most sheet materials
between 0.5mm and 100mm thick.
The hardness of the material will be
determine the maximum thickness.
58. DESIGN CONSIDERATIONS
Reducing cycle time reduce the cost of
water jet process.
Sharp corners slow down the process; the
water jet cutter will slow down to avoid
drag.
59. COMPATIBLE MATERIALS
Mild steel, steanless steel and tool steel
can all be cut with high accuracy.
Titanium, aliminium, copper and brass are
suitable for complex profiles and can be
cut rapidly with this process.
61. ENVIRONMENTAL IMPACT
Offcuts in most materials can be cycled
of re-used
The water is usually tapped from the
mains and is cleaned and recycled for
continous use.