60 years of Conard Corporation’s Photochemical Machining Expertise for Precision Metal Components

For designers and engineers working with precision metal components, selecting the right manufacturing process is critical. Whether you're designing intricate filtration media, thin metal parts for aerospace applications, or precision electronic components, photochemical machining (PCM) offers a versatile and high-precision alternative to traditional methods like stamping, laser cutting, or wire EDM.

One of the leading companies specializing in PCM is Conard Corporation. With decades of expertise, Conard provides cutting-edge etching solutions for industries requiring intricate and accurate metal components. This blog will explore how Conard’s photochemical machining process works, its advantages, and key applications for engineers and designers.

Understanding Photochemical Machining at Conard Corporation

How the Process Works

Conard Corporation uses a sophisticated PCM process that involves:

1. Applying a Photoresist: A light-sensitive film is laminated onto a metal sheet.
2. Imaging & Development: A CAD-designed pattern is projected onto the metal using UV light, hardening specific areas.
3. Chemical Etching: The exposed areas of metal are removed using a controlled chemical etchant, leaving behind the precise design.
4. Stripping & Finishing: The remaining photoresist is removed, and the component is cleaned and inspected for quality assurance.

This subtractive manufacturing method enables exceptional precision without introducing mechanical stress to the material.

Advantages of Conard Corporation’s PCM Process

1. High Precision with Complex Geometries

For engineers needing highly detailed and intricate metal components, Conard’s PCM process can create features as small as 0.004 inches (100 microns) while maintaining tight tolerances. This makes it ideal for precision filters, electronic shielding, and intricate aerospace components.

2. Burr-Free and Stress-Free Manufacturing

Unlike mechanical methods like stamping or CNC machining, PCM does not generate burrs or introduce material stress. This is especially important for thin metals, where warping or cracking can compromise part performance.

3. Rapid Prototyping & Cost-Effective Production

With low tooling costs and the ability to quickly modify photomasks, PCM is perfect for rapid prototyping and low- to mid-volume production runs. Engineers can efficiently test new designs without the expense and lead time associated with hard tooling.

4. Wide Material Compatibility

Conard Corporation can etch a range of metals, including:
✔ Stainless steel
✔ Aluminum (a rare capability in PCM)
✔ Copper and brass
✔ Nickel alloys
✔ Silver and Molybdenum

For applications requiring corrosion resistance, conductivity, or high strength-to-weight ratios, Conard offers PCM solutions tailored to the material’s properties.

5. Scalability for High-Volume Production

While PCM is ideal for prototypes, it is also well-suited for high-volume manufacturing. Conard’s process ensures consistent quality and repeatability, meeting the rigorous standards of industries like aerospace, medical devices, and defense.

Key Applications of Conard Corporation’s PCM Solutions

Aerospace & Defense

• Lightweight, high-strength components for aircraft and defense applications.
• Precision EMI/RFI shielding for electronic systems.
• Fuel and hydraulic system filtration media.

Medical & Life Sciences

• Microfluidic components for lab-on-chip devices.
• Surgical instrument filters with precision hole patterns.
• Fine metal meshes used in drug delivery and medical implants.

Electronics & Telecommunications

• EMI/RFI shielding for sensitive electronic equipment.
• Lead frames and contacts for semiconductor manufacturing.
• Precision apertures and connectors for high-frequency applications.

Filtration & Energy Systems

• Custom perforated plates and screens for fuel cells and battery technology.
• Fine metal filters for industrial, aerospace, and chemical processing.
• Thin precision shims and spacers used in fluid systems.

Why Engineers & Designers Choose Conard Corporation

Conard Corporation stands out among PCM providers due to its technical expertise, advanced capabilities, and commitment to precision. Here’s why engineers trust Conard for their precision metal components:

✔ Decades of Experience: Over 60 years of specialization in photochemical machining.
✔ Industry Certifications: AS9100 Rev D and ISO 9001:2015-certified, ensuring quality and consistency. Also, ITAR registered.

✔ Customer-Centric Approach: Collaborative design support and material selection guidance.
✔ Unique Aluminum Etching Expertise: One of the few PCM providers capable of etching aluminum, a crucial capability for aerospace and electronics industries.

Getting Started with Conard’s Photochemical Machining Services

If you’re an engineer or designer working on high-precision metal components, partnering with Conard Corporation ensures access to state-of-the-art etching capabilities, quick turnaround times, and expert support.

Next Steps:

🔹 Visit www.conardcorp.com to explore their services.
🔹 Request a design consultation to optimize your part for PCM.
🔹 Download their etching design guide to ensure manufacturability.

By leveraging Conard Corporation’s photochemical machining process, engineers and designers can achieve superior precision, cost-efficiency, and performance for their next-generation products.