In precision engineering, even the smallest deviation can lead to catastrophic system failure. Shims, washers, and gaskets are the essential spacers and seals that ensure mechanical assemblies fit perfectly and operate reliably. However, as tolerances tighten in the aerospace, medical, and automotive sectors, standard “off-the-shelf” hardware often fails to meet the required specifications.
Chemical photo etching has revolutionized the production of these flat components, providing a level of dimensional accuracy and material integrity that traditional stamping and laser cutting simply cannot match.
The Critical Role of Precision Spacers and Seals
While they may seem like simple components, the performance of a high-speed turbine or a surgical instrument depends on the quality of its shims and gaskets:
- Shims: Used for ultra-fine adjustments to take up “play” or gap between components, ensuring perfect alignment.
- Washers: Distributed load-bearing components that prevent surface damage and provide vibration resistance.
- Gaskets: High-precision seals designed to prevent leaks between mating surfaces under varying pressures and temperatures.
Why Photo Etching is the Superior Choice for Shims and Gaskets
Traditional manufacturing methods like power stamping apply massive mechanical force to metal sheets. For thin-gauge components, this often results in “edge roll,” burrs, and internal stresses. Photo etching offers a sophisticated, non-mechanical alternative.
1. Zero Edge Deformation or Burrs
For a shim to provide an accurate adjustment, it must be perfectly flat. Stamping often leaves a slight radius or “burr” on the edge, which can throw off measurements by several microns. Photo etching removes metal chemically, resulting in perfectly vertical profiles and burr-free edges straight out of the process.
2. Stress-Free Manufacturing
Mechanical cutting and laser heating can alter the molecular structure of the metal, leading to warping or “oil-canning.” Because photo etching is a cold, non-contact process, the physical properties of the material remain unchanged. This is critical for gaskets that must maintain a perfectly flat seal across their entire surface area.
3. Ultra-Thin and Complex Geometries
Do you need a gasket with intricate internal porting or a shim as thin as a human hair? Photo etching excels at processing foils as thin as 0.010mm. Furthermore, adding complex internal cutouts, holes, or identification numbers (part marking) does not increase the cost, as the entire design is etched simultaneously.
4. Cost-Effective Prototyping
In the development phase, you may need a variety of shim thicknesses to test an assembly. Traditional tooling for stamping is prohibitively expensive for short runs. Photo etching uses digital tooling, allowing for rapid design changes and low-volume production without the burden of “hard tool” costs.
Material Diversity for Every Application
At BlazeAsia, we produce shims and gaskets from a wide array of industrial metals tailored to your specific environment:
- Stainless Steel (Full Hard/Annealed): For corrosion resistance and high-strength spacing.
- Beryllium Copper: Ideal for conductive washers and spring-loaded shims.
- Brass and Bronze: Frequently used in marine and low-friction applications.
- Aluminum: For lightweight spacing and thermal conductivity.
- Titanium: Reserved for high-performance aerospace and medical grade seals.
Secure Your Assembly with BlazeAsia
Precision is not just about the large parts; it’s about the components that hold them together. Whether you require custom-branded washers, multi-layered gasket sets, or ultra-thin precision shims, our photo etching process ensures that every part is delivered to your exact CAD specifications.
Our engineering team is ready to help you optimize your designs for manufacturability, ensuring you get the highest quality components with the shortest possible lead times.
Visit www.blazeasia.com for more information.