Overview

Filter screen chemical etching produces filter media by dissolving holes through sheet metal in a controlled photochemical process. Both faces of the sheet are coated with dry-film resist, the aperture field is exposed and developed, and the unprotected metal dissolves in a matched etchant until every hole matches the artwork. Aperture, pitch and open area come from the drawing rather than from wire count, so the filtration rating of the media stays repeatable from sheet to sheet. Screens run from 0.05 mm to 1.5 mm thick in stainless steel 304/316L, nickel and titanium, with apertures from 0.05 mm and webs down to 0.05 mm on 0.1 mm stock.

Process engineers prefer filter screen chemical etching over woven or punched media for three reasons. Etched holes are uniform and true, so flow and pressure drop behave as calculated. The sheet stays flat and burr-free, which lets a gasket seal evenly across the whole face instead of leaking over crimped wires. And screens come out cleanable: smooth hole walls and stainless, nickel or titanium stock survive repeated cleaning cycles without shedding particles. Filter screen chemical etching therefore fits water, air, chemical and polymer lines where media must be measured, replaced and matched to a defined rating.

Parameter Window

• Available Materials: stainless steel 304/316L, nickel, titanium
• Material Thickness Range: 0.05–1.5 mm
• Tolerance: ±0.02 mm on aperture and pitch, ±0.05 mm on outline
• Minimum Feature: 0.05 mm aperture and 0.05 mm web width on 0.1 mm stock
• Surface Options: electropolishing, passivation, deburring, flattening, gasket bonding
• Compliance: ISO 9001 process control, RoHS/REACH material traceability

Manufacturing Process / Workflow (8 Steps)

1. Media Review — Confirm aperture, pitch, open area, flow direction and screen outline against the filtration duty.
2. Material Selection — Pick the alloy for the media: 316L for general fluids, nickel for alkalis, titanium for seawater and aggressive chemistry.
3. Cleaning & Lamination — Degrease both faces and laminate dry-film resist so fine webs carry no bubbles or pinholes.
4. UV Exposure — Expose through high-resolution film registered to the sheet edges for panel-level pitch accuracy.
5. Development — Open the full aperture field uniformly, then inspect for blocked holes or residual resist on webs.
6. Etching — Spray etchant from both sides at controlled temperature and line speed, compensating undercut so holes stay straight through thick stock.
7. Stripping & Finishing — Strip and neutralize, then electropolish, passivate, flatten or bond gaskets as the assembly requires.
8. Inspection & Packaging — Measure aperture, pitch and open area on optical equipment, then pack flat with protective liners and a first-article report.

Core Advantages

1. Uniform aperture: Every hole matches the artwork, so filtration rating and flow capacity stay predictable across the batch.
2. Flat sealing face: The sheet remains level, letting gaskets and O-rings seal evenly instead of leaking over crimped woven wire.
3. Burr-free media: Smooth hole walls release no particles and trap no contamination, which keeps downstream fluid clean.
4. Repeatable open area: Pressure drop and flow rate hold between batches, so screens can be replaced without retuning the system.
5. Thin and thick gauges: From 0.05 mm foils to 1.5 mm plates, the same process keeps aperture control at both ends.
6. Corrosion-resistant stock: Stainless 304/316L, nickel and titanium cover water, alkalis, seawater and hot process streams.

Typical Applications

• Water and fluid filter discs: Flat discs with uniform holes for housings, strainers and inline filter cartridges.
• Air intake and exhaust screens: Protective media for fans, enclosures and sensor ports that must breathe freely.
• Polymer melt screens: Fine aperture screens upstream of extrusion dies and spin packs where plugging must be visible.
• Hydraulic return screens: Debris-catching media in lubrication and hydraulic circuits with defined cut points.
• Sampling and analyzer screens: Clean, particle-free media for gas and liquid sampling paths.
• Process strainers for food and beverage lines: Flat sieves that clean and reuse without losing aperture shape.

Design Notes & Process Considerations

1. Aperture versus thickness: Keep aperture at or above 1× sheet thickness for straight through-holes; tighter ratios need two-sided etch control.
2. Open area versus strength: Higher open area lowers stiffness and burst resistance; state differential pressure in the drawing.
3. Rating tolerance: When a filtration rating must hold, state aperture tolerance (±0.02 mm) rather than a nominal hole size alone.
4. Sealing features: Flanges, gasket grooves and bonding borders belong in the artwork so they etch with the aperture field.
5. Flow direction: Mark the intended flow side; one-sided lead-in helps cleaning and keeps debris on the inlet face.
6. Cleaning and reuse: Specify electropolishing and passivation when screens must be cleaned and reused over long service.