What is an Alternative for Bag Filter?
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Generally, the terms diffuser, sieve, separator, and bag filter, etc., represent a 3D structure or surface with several small apertures. The objective of a designer is to design maximum functional geometry in a particular construction volume or a specific surface. The ultimate design must create functional apertures without carrier material in the middle. If it is in the middle, it will act as a functional element’s adaptor to the prevalent physical-chemical process conditions.
Industrial etching is an alternative for these filters and diffusers. Today, we will discuss industrial etching, a replacement of bag filter, and diffuser.
Industrial etching is a highly accurate subtractive fabrication process. It uses temperature-regulated etching chemicals for selectively removing materials for the production of highly precise metal components in different shapes. Industrial etching is the most cost-effective fabrication technique than other methods, like laser cutting, water jetting, CNC, and stamping, etc. It also has better lead time, no deburring need, and additional design flexibility.
It is the most optimal solution for highly accurate metal part fabrication, regardless of industrial production or prototyping. There are many reasons why it has become a perfect replacement for the bag filter and diffuser techniques in many situations. Now, let’s take a closer look at the industrial etching process.
The industrial etching process involves different steps; Cleaning > Laminating > Exposing > Developing > Etching > and Stripping. After that, a thorough inspection occurs automatically on all parts. A substrate (sheet of metal) is laminated in the first step with the help of a layer that is light-sensitive material. After that, the photoresist is exposed to ultraviolet light to obtain the product’s positive image.
We get a metallic product once the patterned substrate is exposed to the etching solution that eliminates the exposed components selectively from the substrate. All steps are carried out at highly well-controlled working conditions to ensure the most optimal result.
It is essential to know why you should consider industrial etching as an alternative to the bag filter and diffuser. Industrial etching is an ideal choice for creating complex, high-precision, and multi-layer metal parts. Other methods are not as feasible as it is in terms of accuracy and speed. The etched features tolerance is usually +/- 10%.
Example: When you chemically etch a 200μm part, there could be an up to 0.02mm (20μm) deviation. Industrial etching is best suited in situations where you need sharp edges, round holes, and profiled or straight edges.
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Take a look at the following key benefits of industrial etching:
Industrial etching has the ability of digital tooling. It creates the dimensions of the part with CAD software. After that, it is plotted onto the Mylar film. The engineer can generate the same pattern on the tool for maximizing the number of parts per sheet, reducing the project time.
The second advantage of industrial etching over the bag filter is its high precision machining. The industrial etching does not impact the grain structure, ductility, or hardness of the metal. It results in uniform and precise parts.
Industrial etching is a highly cost-effective method than other machining processes. You will quickly produce phototools with extreme durability. Repeating the process with high precision makes the production run faster, lowering the overall costs.
From large-scale production to prototyping, industrial etching provides a perfect alternative for conventional machining processes like EDM (electro-discharge-machining), CNC machining, pressing, Stamping, Laser Cutting, and Wire Erosion. It is because the industrial etching has flexible scalability and tooling. You can produce prototypes from drawings in just a few days.
Industrial etching is ideal for an array of materials. You can produce almost any metal with the help of industrial etching. These materials include:
Stainless Steel: An array of austenitic, ferritic, and stainless steel
Aluminum: Including aerospace/aircraft grades
Nickel Alloys: Mu-Metal, Inconel, Invar, and Alloy 42
Copper: C101 and C110 (oxygen-free)
Steel: carbon steel, spring steel, tool steel, and mild steel
Others: Molybdenum, brass, nickel silver, beryllium copper, and phosphor bronze
Apart from the above-listed materials, there are also many others that you can use for industrial etching. Its flexibility is a significant reason it has become a replacement for the bag filter and diffuser.
Industrial etching has become a necessity across many industries. It can be the ideal solution when looking for a highly accurate method for producing perfect metal parts. With this, you can create complex, burr-free, and stress-free pieces in only a few days. Therefore, precision and time efficiency are the two significant benefits that come with it.
Take a look at the following application areas of industrial etching in different industries:
Industrial etching is a perfect process for creating different electronics and semiconductor components. Those include lead frames, RFI/EMI shielding cans, SMT stencils, bus bars, spacer, washer, shim, apertures, heat sinks, and flexible circuits.
Several medical tools and components are made with the help of industrial etching technology. Surgical blades, micro-needles, and lancets are a few examples. Therefore, industrial etching also plays a vital role in the medical industry.
You will also find industrial etching playing an essential part in the automotive industry. It helps in creating high-quality automotive parts with precision. Some automotive components made with industrial etching include flat springs, speaker grilles, flexure, etc.
Therefore, industrial etching has become essential for creating a broad range of products across various industries including, medical, automotive, and electronics. Technology is getting better every day, and we need absolute perfection in every product we create. Industrial etching does it for you inexpensively and quickly.
We hope this article should help decide whether you should keep using the bag filter and diffuser process or switch to industrial etching. There are so many advantages to reap with industrial etching that makes it a far better alternative to many other techniques. Keep visiting us for more informational content.
