Metal Roll To Roll Continuous Etching For Precision Metal Parts
Description of Roll to Roll Continuous Etching:
What is Roll to Roll Continuous Etching?
Roll to roll continuous etching, also called reel-to-reel etching, is a high-efficiency process where metal coils are continuously fed through the etching line and collected onto another reel. This method is ideal for mass production of thin, intricate, and highly precise components, including lead frames, connectors, and fine meshes.
Materials of Roll to Roll Continuous Etching:
| Material | Typical Etching Thickness | Maximum Etchable Thickness (Limit) | Application Examples |
| Stainless Steel | 0.02 – 0.25 mm | ~0.3–0.5 mm | Precision filters, bipolar plates, medical components |
| Copper | 0.02 – 0.2 mm | ~0.3 mm | Flexible circuits, electronic shielding, connectors |
| Aluminum | 0.02 – 0.2 mm | ~0.3 mm | Lightweight aerospace parts, electronic components |
| Titanium | 0.02 – 0.15 mm | ~0.2 mm | Medical implants, electrodes, aerospace components |
| Nickel | 0.02 – 0.2 mm | ~0.25 mm | Battery electrodes, precision meshes |
| Alloys (e.g., Ni alloys, Cu alloys) | 0.02 – 0.2 mm | ~0.25 mm-0.3mm | High-temperature filters, corrosion-resistant parts |
How Does Roll to Roll Continuous Etching Work?
Roll-to-Roll (R2R) continuous etching is a high-efficiency manufacturing method designed for large-scale production of precision metal parts. Instead of processing individual sheets, a continuous metal coil moves through each stage of the line in one uninterrupted flow.
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Unwinding – The metal coil is fed into the production line.
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Cleaning – Oils, oxides, and surface contaminants are removed.
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Coating – A uniform photoresist layer is applied.
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Imaging – Patterns are transferred using UV exposure.
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Etching – Unprotected metal areas are chemically dissolved.
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Stripping – Residual photoresist is removed.
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Rewinding – The processed strip is rolled up for inspection or downstream assembly.
This streamlined process ensures high throughput, consistent quality, and reduced production costs, making it especially suitable for industries such as electronics, automotive, filtration, and medical devices.
Advantages of Roll to Roll Continuous Etching
- High Throughput & Efficiency
Continuous processing allows large volumes of metal strips to be etched quickly, reducing production time compared to sheet-by-sheet methods - Consistent Quality
Uniform coating, precise pattern transfer, and controlled etching conditions ensure high repeatability and minimal defects across the entire coil. - Cost-Effective Production
Reduced material handling, less labor, and faster cycle times lower overall manufacturing costs. - Flexibility for Complex Designs
Fine patterns, micro-slits, and intricate geometries can be achieved on thin and flexible metal substrates. - Scalable for Mass Production
Ideal for electronics, automotive components, precision filters, and medical devices where high-volume output is required. - Reduced Material Waste
Continuous processing minimizes scrap and allows better utilization of metal strips.
How to custom your metal parts by Roll to Roll Continuous etching from us?
1. Please send us your design.
We accept the following file formats:DWG, DXF, PDF, STP, Gerber, IGES, CorelDraw and Adobe Illustrator.
2. Samples making lead time:3-10days
3. Express:By DHL, FedEx, TNT, around 3-7days.
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Metal Roll To Roll Continuous Etching For Precision Metal Parts Images
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