Diffusers
Etched metal diffusers support targeted flow control in lines and tubes. Precise geometries help maintain turbulent flow and guide media evenly.
Etching metal diffusers
Etching technology can be used to produce a wide variety of diffusers that help you keep your flow in the turbulent range. Precise diffusers/flow disruptors in lines and tubes prevent the formation of laminar flow, promote plug flow, and keep the homogeneity of the medium unaffected.
Thanks to the high design freedom and the many geometric options that come with etching technology, we can find the right solution for your application. The high precision and burr-free nature of the etched parts ensure that the desired flow profile is achieved exactly.
Your benefits
at a glance
- Implementation of complex designs
- Maximum precision
- No unwanted flow disruption due to conical hole geometries
- Flow deflection through angled hole geometries
- Cost-effective even for small quantities thanks to low tooling costs
- Support in the design concept through years of know-how
- Wide range of metal types
Photochemical etching process for precision metal parts
Photochemical etching produces highly precise metal components with the finest structures and complex geometries. The technology works with extremely tight tolerances, very thin metal sheets, and burr-free results. This enables components that are often not possible with other processes. The finest structures are etched directly from thin sheet metal. The process is characterised by excellent repeatability, high precision, and industrial scalability.
In photochemical etching, metal is structured using a precise lithography and etching process.
The finest contours are created directly from thin sheet metal. The process enables complex geometries without mechanically stressing the material.
The result is stress-free, burr-free components with very high dimensional accuracy.
Our etching process offers virtually unlimited design freedom.
Photo-etching can be used to create a wide range of structures – for example:
• Filtered structures
• See-through structures
• Sharp and smooth edges
• Channelled geometries
With specially developed mask technology, the etching progress can also be controlled in the third dimension.
This creates defined breakthrough geometries and complex components – for example, for lancets, scalpels, or blades in high-volume production.
Photochemical etching enables maximum precision while maintaining high production capacity.
Typical features of the technology:
• Extremely tight tolerances in the hundredths of a millimetre range
• Finest structures and thinnest metals
• High repeatability of results
• Industrial high-volume production possible
The combination of precise lithography and industrial production technology ensures stable processes and cost-effective manufacturing.
In reel-to-reel etching, metal parts are manufactured continuously in an endless strip.
The components are then available as metal strips wound onto reels and can be further processed automatically.
Typical characteristics:
• Metal strip thicknesses of approx. 25 µm to 400 µm
• Easy integration into automated manufacturing processes
• Defined markings or codings possible
The components can be singulated at the customer’s site or fed directly into the next process step.
Photochemical etching can be used to process various metals and alloys.
Standard materials:
• Stainless steel
• Copper
• Nickel
• And its alloys
Additional materials (depending on location):
• Aluminium
• Titanium
• Molybdenum
• Precious metals such as gold or silver
Typical process parameters:
• Material thickness: approx. 0.003 mm to 1.5 mm
• Minimum tolerances: down to ± 0.007 mm
• Minimum web width: approx. 0.5 × material thickness
These values are guidelines and may vary depending on the application.
Our standards are industry-leading
We operate in the world of tightest tolerances, hundredths of a millimeter, finest structures, thinnest metals, and most complex geometries. We etch custom metal components in industrial large series while adhering to the tightest tolerances.
We strive for the highest customer satisfaction through excellent quality. To ensure this, our processes are continuously monitored and further developed through strict quality controls.
Together
to the right solution
The metal specialists of the Wickeder Group combine their strengths to offer you the best in metal. A wide range of standard and customized solutions is available on three continents: Europe, America, and Asia. Through the product and service-oriented business model, the highest quality standards, necessary flexibility, and fast response times are consistently maintained.
Micro Component
Here you will find an overview of additional product solutions relating to etching, laser cutting, or electroforming:
Your contact with us
Do you need further information on the production of diffusers, or do you have a specific task? We look forward to your enquiry.