Microsoft Word - USB TEMP PROBE.doc Matching the cutting or etching process to the number of units is the key to lower product development costs when it comes to thin metal parts.
Laser cutting thin metal parts is often most cost-effective for the small volumes associated with prototyping and initial production, but according to Jim Cove of Mastercut Technologies, the transition to greater production volumes generally demands a rethink.
"As the unit volumes increase, there may come a point where stamping becomes an option," said Cove. "But when you crunch the numbers on tooling costs, having the right punch, handling and other issues, you may find yourself laser cutting for longer than you thought."
Photochemical milling, a less well-known intermediate step, provides very economical components without limiting your ability to alter the design along the way, Cove added.
The PCM process exposes the image of the required parts onto light-sensitive film laminated to the material of the parts. Once developed, only the exposed areas of film remain in place.
After a series of passes through the acid etching machine, the areas unprotected by the film simply disappear, leaving only the wanted components.
The parts are secured with carefully placed “tabs” that allow the part to snap out of the sheet easily, often without leaving any sharp edges.
"PCM is the closest thing to 'photocopying' of metal parts — and brings all its advantages," Cove continued. "The etching process takes no longer per sheet regardless of the intricacy or number of parts.”
He said another major advantage is the ability to partially etch or to include fold lines, holes, slots, mesh, text, and logos without significantly increasing the process time or cost.
Supplied by Mastercut Technologies
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