The Photochemical Maching (PCM) process lends itself to designs of low to medium volumes of metal parts from very basic designs to those which are intricate, thin and difficult to handle. In most cases, “If it can be drawn, it can be etched,” is considered the extent of the process’ design capabilities. Most PCM applications produce precise flat metal blanks which can then be formed into various exotic 3-D shapes.
Although the PCM process lends itself well economically to experimental, prototype, and low-to-middle range production runs, it is also capable of large volume applications where the unique advantages of the PCM process can be taken advantage of. Because of the Fast Turn Around, Low cost Lifetime Tooling , the PCM process is very appealing when compared to stamping dies. Parts that are blanked by the PCM process range from flat springs, electronic lead frames, medical implants, and pump valves to highly ornate decorative parts.
Low Lifetime Tooling costs are only the beginning of the advantages of the PCM process. The photographic tool can be produced within hours of receipt of a CAD drawing and production can begin as soon as the metal is prepped and the tool is accepted. In addition, engineering changes to the tool configuration (if required) can be performed in hours with minimal costs and delays. Therefore, critical time-to-market considerations are substantially reduced.
The photo tool lends itself to a multiplicity of designs whereas multiple images of the same or different designs can be incorporated into the photo tooling. The same photo tool used to produce prototype quantities can be used for higher volume runs to provide precise reproduction of the required design during production runs.
Since the PCM process “dissolves” metal during parts formation, edge burrs do not exist. Nor does it alter the metal characteristics, as is the case with laser cutting or the EDM processes (recast layer) therefore; costly and time consuming de-burring processes are eliminated.
Because the metal is dissolved during the PCM process, the original characteristics of the metal such as hardness, grain structure, magnetic properties and ductility are not changed during the process. The metal characteristics are the same from the beginning to end of the process, resulting in Burr Free, Stress Free, Strain Free parts in any temper of material.
When metal pieces are formed into shapes after the initial PCM process, ”half-etched” bend lines can be incorporated into the photo tool. The subsequent “half-etched” areas are produced on one side of the metal and provide precise location points for forming into the final configuration.
