micrometal demonstrates the capabilities of next-generation photochemical etching technology in the production of an ophthalmic blade
(April 26, 2023, Müllheim, Germany)The leading innovator in photochemical etching (PCE), micrometal, is pleased to demonstrate the capabilities of its next-generation precision metal processing technology through recent work with a manufacturer of ophthalmic devices featuring integrated surgical blades.
PCE offers several specific advantages in the production of delicate blades for eye surgery. Firstly, it enables the creation of extremely precise and complex blade designs with sharp cutting edges and tight tolerances, ensuring the highest level of accuracy and consistency during surgical procedures. This is particularly crucial in eye surgery, as even minor deviations in blade design can have significant impacts on treatment outcomes.
Secondly, PCE enables the production of extremely thin blades – down to a few micrometers in thickness – as required for many types of eye surgeries. These blades can be manufactured without burrs or rough edges, ensuring a smooth and precise cut.
Furthermore, the PCE process is a chemical, non-contact method that applies no mechanical force to the metal during manufacturing. This reduces the risk of deformation or damage to the blade. This is particularly important when processing thin, delicate blades that require the highest precision.
Jochen Kern, Head of Sales and Marketing at micrometal, states: “For manufacturers of delicate metal parts and components, choosing the right technology is crucial to ensure high-quality, precise, and cost-efficient production. micrometal’s next-generation PCE process stands out as the preferred technology for several reasons – primarily due to its unparalleled precision, which enables the production of geometrically complex designs and shapes with tight tolerances that would be difficult or impossible to achieve with conventional manufacturing techniques. Additionally, PCE is extremely versatile, allowing for the processing of a wide range of metals and material thicknesses, and is comparatively fast and cost-efficient – with low tooling costs, short lead times, and components that are free of stress and burrs.”
micrometal has further optimized an already precise technology. The company’s process-related advantages enable structural sizes of just 25 micrometers, a minimum hole diameter of 80% of the material thickness, and repeatable tolerances in the single-digit micrometer range. It was precisely these characteristics that convinced the ophthalmic device manufacturer, who specifically wanted to develop a surgical instrument and system for extremely precise interventions – such as cataract removal and vision correction. The blade is used to penetrate the lens tissue of the eye with minimal tissue damage, which supports better healing and allows for either the mechanical removal of tissue or the correction of internal eye structures.
Kern adds: “We worked intensively to achieve the extremely demanding tolerances of the ophthalmic device manufacturer. The customer found that our etched blades were the sharpest they had ever seen. Compared to conventional mechanical grinding, PCE produces a very smooth and sharp cutting edge. Under the microscope, mechanically sharpened edges show fractures and rough structures due to process-related influences and brittle material conditions caused by work hardening. In contrast, the combination of liquid photoresist and micrometal’s high-resolution mask technology creates an extremely sharp cutting edge that does not ‘tear’ the tissue.”
micrometal’s next-generation PCE process uses a unique and patented wet-film etching system, where the coating is only 2–8 micrometers thick – in contrast to conventional dry PCE coatings of 10–50 micrometers. Liquid photoresist is better suited for high-precision manufacturing processes and leads to higher reproduction accuracy.
micrometal’s high-resolution glass photomasks are manufactured at 100,000 dpi and offer significantly better imaging accuracy and resolution than film phototools used in conventional etching processes. By using glass masks, the company can realize applications such as the ophthalmic blade described here, which require extreme precision and would not be achievable with conventional PCE. Glass phototools allow for tolerances in the range of 1–2 micrometers (hole tolerances of < 1 micrometer are possible) and avoid distortions due to environmental influences such as humidity, which often occur with film tools.
Learn more about our solutions here.
