Overview

A high precision atomizer mesh photo chemical etching order usually covers two kinds of precision metal parts at once, so our plant runs both precision electroforming and photo chemical etching lines. It is important to be clear: the thousands of micro-holes in the mesh itself are formed by precision electroforming, not by etching. Nickel or nickel-iron is electro-deposited onto a conductive mandrel patterned with the hole array, then peeled off as an ultra-thin foil with smooth, burr-free, uniform apertures. The accompanying alignment frames, deposition masks and support shims, by contrast, are produced by photo chemical etching, which opens registration holes, windows and stiffening ribs in thin metal sheet.

For sourcing and design engineers, this split solves three limits of a single process: micro-holes down to a few tens of microns are too dense and too small for stamping or laser cutting, which leave burrs, blocked holes or heat distortion that ruin droplet uniformity; an ultra-thin foil wrinkles on its own and needs a frame and support shim to hold tension and provide a datum; and the mask-to-mesh registration that governs spray consistency is hard to guarantee when parts are bought from separate vendors. Keeping the electroformed mesh and the etched frame parts under one drawing and inspection system lets hole size, frame position and alignment marks be matched in a single pass.

Parameter Window

• Available Materials: electroformed nickel, nickel-iron alloy, 316L stainless mesh; frames and masks in 304/316L, copper, nickel
• Material Thickness Range: 0.02–0.20 mm mesh foil, 0.10–0.50 mm frame and support stock
• Tolerance: ±0.005 mm on hole diameter, ±0.01 mm on hole pitch, ±0.02 mm on frame position
• Minimum Feature: 0.03 mm hole diameter, 0.05 mm hole pitch, up to several thousand holes per cm²
• Surface Options: electropolished, nickel/gold plating, hydrophobic and oleophobic coating, anti-clog treatment
• Compliance: ISO 9001 process control, RoHS/REACH material traceability

Manufacturing Process / Workflow (8 Steps)

1. Drawing Split — Separate customer data into the mesh hole array and the frame outlines, and confirm hole size, pitch and alignment datums.
2. Mandrel Prep — Build a photolithographic mandrel on a conductive substrate that defines the micro-hole pattern, checking wall verticality and cleanliness.
3. Precision Electroforming — Electro-deposit nickel or nickel-iron onto the mandrel, controlling current density and bath chemistry to grow the ultra-thin mesh foil.
4. Peeling & Cleaning — Release the electroformed foil from the mandrel, strip and clean it, then inspect hole uniformity for blockages or pinholes.
5. Frame Lamination — Hot-roll dry film onto both faces of the frame, mask and support sheet with no bubbles under fine ribs.
6. Exposure & Development — Expose the frame outline through high-resolution film, develop to open the metal to be removed, and check registration holes.
7. Etching — Spray chemistry matched to the frame alloy; time, temperature and line speed govern the photo chemical etching of windows and stiffening ribs.
8. Assembly & Inspection — Bond mesh to frame on the alignment marks, verify hole size, concentricity and flatness, then pack on liner or in trays.

Core Advantages

1. Micro-holes by electroforming: Apertures grow in one precision electroforming step with smooth, burr-free walls, so hole size and droplet uniformity stay consistent.
2. Ultra-thin yet flat: Deposited foil is controlled down to tens of microns yet stays flat, and the frame holds it under tension without collapse.
3. Very high hole density: 0.03 mm class holes at thousands per cm² are replicated faithfully for high atomization efficiency.
4. Matched companion parts: Alignment frames, masks and support shims are made by photo chemical etching and share the mesh datum, so assembly stays concentric.
5. No burrs, no blocked holes: Neither electro-deposition nor chemical removal adds dross or roll-over, so open area stays high and holes resist clogging.
6. One source, two processes: Electroformed mesh and etched frame parts are aligned under one system, cutting multi-vendor back-and-forth.

Typical Applications

• Medical nebulizer meshes: Core micro-hole foils for portable inhalers, electroformed for uniform apertures and fine, even drug droplets.
• E-vapor atomizer cores: Micro-hole guide meshes beside heating elements, paired with etched support shims for stable, leak-free vapor.
• Aroma and humidifier modules: Ultra-thin, low-resistance foils for home scent devices that resist clogging over long runs.
• Beauty mist meshes: High-density foils for handheld facial misters, giving a soft spray rather than water droplets.
• Deposition masks and frames: Companion windows and alignment frames opened by photo chemical etching for coating and bonding steps.
• Laboratory micro-sieves: Electroformed foils for fine filtration and aerosol generation, with etched rims for easy clamping.

Design Notes & Process Considerations

1. Hole size and pitch: State target diameter, pitch and tolerance; the smaller the hole, the more it depends on mandrel precision, which etching cannot replace.
2. Foil thickness: Give deposited layer thickness and allowed deviation, since it drives flow resistance and foil strength alongside hole size.
3. Open area and layout: Specify hole arrangement and open-area ratio; a hexagonal close pack balances output with foil rigidity.
4. Coating and wettability: Name hydrophobic, oleophobic or hydrophilic coatings so liquid residue does not build up and clog the holes.
5. Frame datum: Frame and mesh should share alignment marks with a stated concentricity, since bonding offset makes the spray off-center.
6. State the process route: Mark the electroformed mesh and the etched frame parts separately on the drawing to avoid mixing up the two routes.