The Role of Photo Etching in the Aerospace Industry: Precision, Durability, and Innovation

The Role of Photo Etching in the Aerospace Industry: Precision, Durability, and Innovation


Introduction to Photo Etching in Aerospace

In the aerospace industry, precision is non-negotiable. From fuel control systems to satellite components, every part must meet exacting standards for performance, durability, and reliability under extreme conditions. Photo etching, also known as photochemical etching or chemical machining, has emerged as a cornerstone manufacturing process for crafting intricate, high-precision metal components. At VACCO Industries, we leverage over 70 years of expertise to deliver aerospace-grade etched parts that power innovation in commercial, defense, and space applications.

This article explores the critical role of photo etching in aerospace, its benefits, applications, and why VACCO’s AS9100-certified processes set the industry standard for quality and precision.


What is Photo Etching?

Photo etching is a subtractive manufacturing process that uses photographic techniques and chemical etchants to shape metal with unparalleled precision. Unlike traditional machining, which relies on mechanical cutting, photo etching employs a photoresist mask to selectively remove material, creating complex geometries without burrs, heat distortion, or stress.

The Photo Etching Process

  • Design: Engineers create a digital design using CAD software (e.g., Autodesk Inventor).
  • Photo Tool Creation: A photographic negative (photo tool) is laser-plotted to exact specifications.
  • Material Preparation: Metal sheets (e.g., titanium, copper, stainless steel) are cleaned and coated with photoresist.
  • Exposure: The photo tool transfers the design onto the photoresist via UV light, hardening or softening specific areas.
  • Etching: Chemical etchants remove unprotected metal, leaving precise components.
  • Finishing: Parts undergo stripping, inspection, and value-added processes like diffusion bonding or laser welding.

VACCO’s advanced facilities in South El Monte, CA, produce parts with tolerances as tight as ±0.0005″, making photo etching ideal for aerospace applications.


Why Photo Etching is Essential for Aerospace

The aerospace industry demands components that are lightweight, durable, and capable of withstanding extreme temperatures, pressures, and corrosion. Photo etching meets these needs through:

1. Unmatched Precision

Photo etching can produce features as small as 0.004″ and work with materials as thin as 0.0003″, enabling the creation of intricate parts like microfluidic channels and multilayer screens. This precision is critical for aerospace components such as fuel valves and EMI/RFI shields.

2. Complex Geometries at Low Cost

Unlike stamping or laser cutting, photo etching’s cost is driven by material dimensions, not design complexity. Complex parts like heat exchangers or satellite grids incur no additional tooling costs, making it cost-effective for prototyping and high-volume production.

3. Burr-Free and Stress-Free Parts

The chemical process eliminates mechanical stress and thermal distortion, producing burr-free parts that require minimal post-processing. This is vital for aerospace applications where imperfections could compromise safety.

4. Material Versatility

Photo etching works with a wide range of aerospace-grade metals, including:

  • Titanium: For lightweight, corrosion-resistant parts like heat exchangers.
  • Aluminum: For weight-saving components in airframes and antennas.
  • Stainless Steel: For durable screens and fuel system parts.
  • Inconel and Copper: For high-temperature and conductive applications.

5. Rapid Turnaround

Photochemical etching enables same-day production of complex parts, reducing lead times compared to traditional methods. VACCO’s digital tooling and Laser Direct Imaging (LDI) further enhance speed and accuracy.


Key Aerospace Applications of Photo Etching

Photo etching supports a wide range of aerospace components, ensuring performance in demanding environments. Here are some key applications:

1. Fuel Control Systems

Photo-etched fuel valves and filters ensure precise fuel delivery in aircraft and spacecraft. VACCO’s patented PhotoPore® screens provide fine filtration for critical systems.

2. Heat Exchangers

VACCO’s multilayer etching and diffusion bonding create compact, high-efficiency heat exchangers for thermal management in satellites and jet engines. Our titanium etching processes excel in producing durable, lightweight exchangers.

3. EMI/RFI Shields

Electromagnetic interference (EMI) shields, etched from copper or stainless steel, protect sensitive avionics from interference, ensuring reliable communication and navigation.

4. Satellite and Spacecraft Components

Photo etching produces lightweight grids, antennas, and battery contacts for satellites. VACCO’s Chemically Etched Miniature Systems (ChEMS®) are used in critical spacecraft applications.

5. Airframe Components

Etched aluminum stiffeners and panels reduce weight while maintaining structural integrity, supporting fuel efficiency in commercial and military aircraft.

6. Decorative Trim

Photo etching crafts intricate interior trim for private and commercial aircraft, combining aesthetics with precision.


Why Choose VACCO for Aerospace Photo Etching?

As the largest commercial photo etching company in the Western United States, VACCO Industries stands out for its:

  • AS9100 and Nadcap Certifications: Ensuring aerospace-grade quality and compliance.
  • Advanced Capabilities: In-house diffusion bonding, laser welding, and micro-laser cutting complement our etching expertise.
  • Large-Scale Production: Facilities handle panels up to 28″ x 68″, supporting high-volume aerospace needs.
  • Environmental Commitment: We recycle all acid and metal waste, aligning with sustainable manufacturing.
  • Custom Solutions: From prototyping to production, our engineers provide design assistance using tools like COSMOS and Ansoft Maxwell 2D.

Our 70-year legacy includes partnerships with leading aerospace manufacturers, delivering components for commercial jets, defense systems, and space exploration.


Case Study: Multilayer Titanium Screens for Aerospace

One of VACCO’s standout projects involved etching multilayer titanium screens for an aerospace client. Using our proprietary etching and diffusion bonding processes, we produced screens with:

  • Thickness: 0.006″ per layer.
  • Tolerances: ±0.0008″ for features and ±0.002″ for hole registration.
  • Application: High-strength filtration in extreme conditions.

The screens were micro-laser welded into 3D assemblies, exceeding industry standards for durability and performance. This project showcases VACCO’s ability to handle complex, mission-critical aerospace components.


The Future of Photo Etching in Aerospace

As aerospace technology evolves, photo etching will play an even greater role in:

  • Miniaturization: Enabling smaller, lighter components for drones and microsatellites.
  • Sustainability: Reducing material waste through precise etching.
  • Innovation: Supporting next-generation designs for hypersonic aircraft and lunar missions.

VACCO is at the forefront, investing in automation, Six Sigma methodologies, and advanced inspection to meet future demands.


Photo etching is revolutionizing aerospace manufacturing by delivering precision, cost-efficiency, and versatility. From fuel systems to satellite grids, VACCO Industries’ photochemical etching expertise ensures components meet the industry’s highest standards. As an AS9100-certified leader, we’re proud to drive innovation and reliability in aerospace applications.

Ready to elevate your aerospace project? Contact VACCO Industries today to discuss your photo etching needs or request a quote. Let’s build the future of flight together.


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Benefits of Photo Etching Metals for the Medical Industry by VACCO

VACCO is the industry leader in photo etching metals, where precision meets innovation. Our photo etching services are particularly advantageous for the medical industry, offering solutions that enhance the performance, reliability, and functionality of medical devices and equipment.

Precision Manufacturing

  • High Precision: VACCO’s photo etching process achieves unparalleled precision, crucial for the intricate components used in medical devices. This allows for the creation of parts with complex geometries and fine details down to microns, ensuring that the devices function with exact specifications.
  • Consistency: With our advanced tooling capabilities using Laser Direct Imaging (LDI), we maintain consistent quality across production runs. This consistency is vital for medical applications where reliability can impact patient health outcomes.

Cost-Effectiveness and Speed

  • Reduced Tooling Costs: Unlike traditional methods like stamping or CNC machining, photo etching requires no hard tooling, significantly reducing both the cost and time for prototyping and small to medium production runs.
  • Quick Turnaround: Our process enables rapid prototyping, with the potential for parts to be shipped within 24 hours under expedited services. This speed can accelerate the development cycle of new medical devices, getting innovations to market faster.

Material Versatility

  • Wide Material Compatibility: VACCO can photo etch a variety of metals such as stainless steel, titanium, copper, and more.  We understand the requirement of biocompatibility and durability . This versatility caters to a broad spectrum of medical device manufacturing needs.
  • Customization: Each medical project has unique requirements. VACCO’s process allows for custom designs and material selections tailored to specific medical applications, from surgical instruments to implants.

Quality and Reliability

  • Burr-Free Components: The photo etching process at VACCO produces parts without burrs or mechanical stress, ensuring that medical devices do not have sharp edges that could compromise safety or functionality.
  • Sterilization Compatibility: The materials and processes used are compatible with various sterilization methods, ensuring that medical devices remain sterile without compromising their integrity.

Applications in the Medical Field

  • Micro Components: Used in microfluidic devices, sensors, and micro-actuators essential for diagnostics or drug delivery systems.
  • Implants and Prosthetics: Precision-etched components that are critical for implants where fit and function must be perfect.
  • Surgical Tools: Customized tools with specific shapes or patterns for enhanced surgical precision.
  • Medical Filters: Fine screens and meshes for filtration in medical devices, ensuring purity and effectiveness of treatments or diagnostics.

Environmental and Safety Compliance

  • Eco-Friendly Process: VACCO’s commitment to sustainability includes recycling etchants and managing waste responsibly, aligning with the medical industry’s environmental concerns.
  • Regulatory Compliance: Our processes and materials are designed to meet stringent medical industry standards, including FDA regulations, ensuring that products are safe for medical use.

At VACCO, we understand the unique demands of the medical industry. Our photo etching technology not only meets but exceeds these demands with precision, speed, and cost-efficiency. Choose VACCO for your photo etching needs and transform the way you approach medical device manufacturing.

Contact Us:

  • Phone: 626.443.7121
  • Email: etch@vacco.com
  • Address: 10350 Vacco Street, South El Monte, CA 91733

What is Laser Direct Imaging (LDI)?

Laser Direct Imaging, also commonly known as LDI, plays a key role in the metal etching process. Traditional etching involves coating the metal plate with a polymer photo resist. After that, the digital design is exposed to the photo resist using ultraviolet light and photo tooling where the dark lines create a pattern on the surface of the photo resist. The sheets are then run through a developing process that removes the polymer resist where the dark images were. The exposed metal is now vulnerable to the acid’s etching action. With laser direct imaging, the process is faster and more accurate. LDI uses a precise, computer-controlled laser beam to imprint the patterns in photo resist on the metal plates replacing the use of artwork and exposure to ultraviolet light.

LDI Process

The process of Laser Direct Imaging takes place in the following steps:

  1. A digital image is created to the customer’s exact specifications, replacing traditional artwork.
  2. Metal is also selected and sheared to size.
  3. Metal is cleaned and then coated with the photosensitive resist.
  4. The coated sheets are placed in the LDI and the digital data or image that is to be etched is exposed to the resist on both sides.

This whole process leaves behind the traditional use of costly artwork. LDI gives us a significantly reduced margin of error, and the result is as accurate as the design uploaded to the laser.

Benefits of LDI

Using Laser Direct Imaging instead of photo-tool helps manufacturers reduce:

• Light refraction problems
• Alignment issues
• Environmental impact

Other benefits include:

• Precise imaging
• Better resolution
• Improved optical alignment
• Quick and hassle-free image changes

Advantages of LDI

• Superior image resolution
• Precise two-sided registration
• The use of Laser ensures clean cut edges
• Able to image large sheets with precision
• It can produce a higher volume of end products by working on multiple sheets concurrently
• Any changes or corrections take only a few minutes and one doesn’t need to send it back

LDI with The LIMATA X3000

VACCO Etch has recently acquired a new machine that provides us with an edge in the competitive market. The LIMATA X3000 series is a Laser Direct Imaging equipment specialized in producing patterns on large sheets. The machine has a multiple wavelength setup, a user-friendly interface, and has great optical depth.

Limata X3000

VACCO Precision Etched Parts is one of the paramount photo etching institutions throughout the western United States. With the addition of LDI, we can offer larger etched sheet sizes, with higher resolution imaging, and more affordable than large panel artwork.

Metals Etched by VACCO-etch

• Stainless steel
• Titanium
• Brass
• Copper
• Nickel alloy
• Carbon & spring steel and
• HyMu

We have in-house diffusion bonding, forming, welding, adhesive bonding, micro laser processes and a highly skilled hand assembly, inspection, and packaging line which allow us to enhance and customize your photo etching project.

What is Diffusion Bonding?

Diffusion Bonding is a metalworking technique in which two metals are joined together by applying dynamic load and heat in controlled conditions. The diffusion of atoms at the interface of two joining metals takes place within these conditions which lead to uniform grain structure joint closing the interfacial voids leading to solid-state bonding.

Diffusion Bonding
IMG_3768
Diffusion Bonding

Why Diffusion Bonding?

Diffusion bonding, used to join two similar metals, is a preferred choice over other metalworking techniques due to its superior bonded surface finish, especially when intricate structures with fine boundaries are involved. Some of the common techniques used in industry and their comparison with diffusion bonding include:

TechniquePrincipal MethodProfile Modification
WeldingHigh-temperature melting and diffusion of two joining metals using filler materialsYes, melting deforms weld joint surface leading to profile modification.
BrazingSimilar to welding but fusion between two joint metals does not take place only filler material is melted between the joining metals to form a bond.Yes, heat and melted filler material will modify the surface profile at joining faces.
SolderingJoining of two metals by using third low melting point material which holds two metals together after hardening.Yes, the melted filler can seep in between and over two joining faces.
Mechanical FasteningRiveting or Nut/Bolt fastening is used where permanent joints are not needed but require a spacious design to accommodate the holes for rivets or bolts. The holes are also stress raisers.No, Joint faces do not undergo any modification.
Adhesive BondingAdhesives are used to glue metal together, these glues could be epoxy or plastic agents and when applied between two metals that are then held under pressure the glue cures to develop a strong bond.Yes, Glues are prone to creep into uneven surfaces and can’t be used for intricate joints with the varying surface feature.
Diffusion BondingJoint faces are kept under pressure and heated to diffuse the atoms across the boundaries of joining faces and hence result in strong bonding.No, Metal surfaces with intricate features can be joined this way and hence can be used for the precision joining of metals with intricate features/flow paths.

In diffusion bonding two metals are joined without liquid fusion, melting, filler materials, or loss of weight and hence the characteristic metallurgical features of the parent metal do not change and the bond so developed is stronger. Diffusion bonding is extremely useful for manufacturing those components that have intricate internal structure or flow paths that will be difficult to machine using conventional manufacturing process when made from single-parent metal block. The component is designed in individual layers that can be etched separately, and in some cases combined with machined layers. These layers are then stacked to be diffusion bonded, creating a multidimensional component.

Diffusion Bonding
Diffusion Bonding Heat Exchanger
Diffusion Bonding Screens

Diffusion Bonding Process

As mentioned above, diffusion bonding is solid-state bonding that means two surfaces that are to be bonded together do not undergo liquid state transition in the process of fusion and hence the process steps must be followed meticulously and when done so the bond is of high quality. The surface preparation, the pressures to be applied, the temperature to be maintained, the hermetic seal requirements and the environment in which to carry out the entire process are critical factors. The simplified steps of diffusion bonding are:

  1. Surface Preparation – Ensure that the two surfaces that are being joined are smooth, debris-free, flat, and degreased. Good surface preparation is essential.
  2. Pressure Loading – The two surfaces are then put together and pressurized to predetermined levels depending on the requirements of the bonded component, and the metallurgical limitations of the metals. This is done in an environment-controlled chamber, in which the process initiates by creating a vacuum to purify the process environment.
  3. Dynamic Heating – The metals are then heated to predetermined levels (lower than the melting point of parent metals) to accelerate the atoms fusion across the boundaries of joining surfaces. The uniformity of temperature is crucial to ensure fusion equilibrium over the whole of the bonding surfaces.

When the process variables are precisely controlled the resultant bond’s strength and ductility matches that of parent metals and when put under tensile test the component should fail at parent metal and not at the bonded joint. The good diffusion bonded component cross-section should be structurally indistinguishable from the bond line and should be void-free.

Stages of Diffusion Bonding

During the entire controlled process of diffusion bonding, the bonding faces undergo the following four key stages:

  1. Initial contact of parent metals.
  2. Plastic deformation of asperities under pressure load due to creep.
  3. Voids disappear as grain boundary diffusion under high temperatures. Grain diffusion plays a major role in plastic deformation.
  4. Elimination of pores by volumetric diffusion.

Application of Diffusion Bonding

Diffusion bonding is used across multiple industries for its ease in manufacturing precision components with complicated internal features. Diffusion bonding can be used primarily with similar metals, metals of different thicknesses, and reactive metals. Common applications are in manufacturing of:

  • Microfluidics
  • Sensors
  • Miniature Heat Exchangers
  • Fuel Cells
  • Medical Devices
  • Electrical Components
  • Fluid Mixing Valve

The high precision offered by diffusion bonding is of the value +/-0.002” which enables its application in the manufacturing of critical components for various industrial applications such as:

  • Aerospace (Avionics/Space)
  • Automotive
  • Electrical Equipment
  • Scientific Equipment
  • Marine (Sensors/Equipment)
  • Electronic Fibers

VACCO offers a complete solution to all these industries from photo etching to diffusion bonding with its expert team of engineers and R&D team that works closely with clients to ensure a high-quality product. VACCO’s photo etching and diffusion bonding capabilities can handle thickness that ranges from 0.001” through 10”, a variety of materials including titanium and iron-nickel alloy. The use of ceramic or molybdenum materials to make fixtures ensures a high-quality finish of the product. The in-house welding and liquid penetrant inspection processes comply with the Performance Review Institute and national Aerospace and Defense Contractors Accreditation Program. VACCO’s Precision Etched Parts group is equipped with an in-house vacuum furnace to handle all your bonding needs. The Vacuum furnace consists of a 12” wide, 12” high and 12” deep hot zone capable of handling temperatures up to 1315℃. For more information and queries related to any of your bonding needs please reach out to us!