Overview

Spray orifice plate etching uses photochemical machining to produce nozzle plates in which every orifice is formed by dissolving metal through a photo-patterned resist, not by drilling or punching. This distinction matters for spray systems because a drilled hole carries a burr on the exit side that disturbs the spray cone, while a punched hole has a tapered or torn edge that changes flow. In spray orifice plate etching the orifices are opened from both sides with the same chemistry, so the entry and exit edges stay sharp, round and identical across the plate, and the resulting spray pattern is uniform and repeatable from nozzle to nozzle.

Orifice plates are typically made from 304/316L stainless steel, nickel 200 or nickel alloys, in thicknesses from 0.05 mm to 0.5 mm. Hole diameters can run down to about 0.02 mm, and because the artwork is exposed from a digital file, hole diameter, pitch and pattern can all change without tooling. This makes spray orifice plate etching the preferred route for fuel nozzles, inkjet apertures, misting heads, agricultural spray tips and medical or cosmetic atomizers, where droplet size, flow rate and cone angle all depend on how precisely the holes are held.

Parameter Window

• Available Materials: 304/316L stainless steel, nickel 200, nickel alloys
• Material Thickness Range: 0.05–0.5 mm
• Tolerance: orifice diameter ±0.01 mm, position ±0.025 mm across the panel
• Minimum Feature: orifice diameter down to 0.02 mm at 0.05 mm stock
• Surface Options: electropolished, passivated, bright or matte nickel plating
• Compliance: ISO 9001 process control, RoHS/REACH material traceability

Manufacturing Process / Workflow (8 Steps)

1. Artwork & Flow Analysis — Convert the nozzle pattern to vector artwork and confirm hole diameter, pitch and total open area against the target flow rate.
2. Material Selection — Choose 304/316L or nickel for corrosion resistance to the sprayed fluid; confirm thickness for the required pressure drop.
3. Cleaning & Lamination — Degrease the sheet and laminate dry film resist on both sides so orifices can be etched from entry and exit.
4. Double-Side Exposure — Expose the pattern from both sides with front-to-back registration to keep holes straight and concentric.
5. Development — Wash out unexposed resist and inspect hole openings under magnification for residue or under-development.
6. Etching — Spray etch with chemistry matched to the alloy, controlling time, temperature and pressure to reach diameter while limiting undercut.
7. Stripping & Finishing — Strip resist, neutralize, then electropolish or plate to smooth edges and improve corrosion resistance.
8. Inspection & Packaging — Measure orifice diameter and position optically, check flow on a sample, and pack in trays or on liner.

Core Advantages

1. Burr-free round holes: Both sides are etched, so the orifice exit has no roll-over burr to deflect the spray and no torn edge to change the droplet size.
2. Tight diameter control: Orifice diameters are held to ±0.01 mm across the panel, so flow rate stays consistent from part to part.
3. Uniform spray cone: Round, centered holes give a symmetrical cone and even coverage without hot spots or streaks.
4. No tooling: Any new hole pattern is a new film, so prototype nozzles and pattern revisions cost nothing to re-tool.
5. Hard-material freedom: Nickel and hardened stainless etch as readily as soft alloys, which drilling and punching cannot match.
6. Full-plate consistency: Every orifice on a sheet etches at the same rate, so diameter and flow match across the entire batch.

Typical Applications

• Fuel and oil nozzles: Precision spray tips where hole diameter sets the atomization and flow rate.
• Inkjet apertures: Fine orifice rows on thin stainless or nickel for drop-on-demand heads.
• Misting and humidification heads: Uniform orifices for fine fog and even humidity control.
• Agricultural spray tips: Wear-resistant stainless tips with consistent droplet distribution.
• Medical and cosmetic atomizers: Small, clean orifices for nasal, ophthalmic and fragrance delivery.
• Chemical dosing nozzles: Corrosion-resistant nickel plates for accurate metering of aggressive fluids.

Design Notes & Process Considerations

1. Orifice diameter versus thickness: Keep hole diameter at least equal to material thickness, or the etch will taper and the spray cone will widen.
2. Undercut allowance: Expect an undercut of roughly 10–15% of thickness per side; add it to the artwork so the finished diameter lands on target.
3. Entry and exit geometry: Specify whether holes are straight through or countersunk, since entry radius changes the spray angle.
4. Open area and flow: State the required flow rate at a given pressure so the hole count and diameter can be balanced.
5. Pitch and web: Keep the land between holes at least 1× thickness to avoid distortion and hole merging during etch.
6. Surface finish: Call out electropolish or plating if the sprayed fluid is corrosive; a smooth exit edge keeps the cone stable.