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How to make precise sheet metal parts (photochemical machining)

Applied Science · Youtube · 23 HN points · 0 HN comments
HN Theater has aggregated all Hacker News stories and comments that mention Applied Science's video "How to make precise sheet metal parts (photochemical machining)".
Youtube Summary
How to make etched metal parts.
-All of the highest quality parts that I made went to the customer, but edge quality and photoresist adhesion is still a problem.

-The photomask dark areas can be expanded, and then the part etched for a longer amount of time to make the edges more perpendicular to the surface. I forgot to mention this clever way to improve the etch aspect ratio called "etch factor" http://www.chemcut.net/wp-content/uploads/2015/03/Chemcut_Thoughts_on_Undercut.pdf

-Dry film photoresist https://www.amazon.com/30cm%C3%975m-Portable-Photosensitive-Production-Photoresist/dp/B07MMVPY1Z/

-Photoresist processing datasheet https://www.dupont.com/content/dam/dupont/amer/us/en/products/ei-transformation/documents/DEC-Riston_GeneralProcessingGuide.pdf

-Special ink and transparencies (films) for photomasks: https://filmdirectonline.com/

-Flip pins https://shop.evilmadscientist.com/productsmenu/853

-405nm lights: https://www.amazon.com/gp/customer-reviews/R2BR1XN80FQT9R/

-Epson printer with tank for custom ink: https://epson.com/For-Work/Printers/Inkjet/EcoTank-ET-M1170-Wireless-Monochrome-Supertank-Printer/p/C11CH44201

-Strange Parts did a great video on metal business cards: https://www.youtube.com/watch?v=83GDV0xsTTs

-https://mymetalbusinesscard.com/product/stainless-steel-business-cards/ 100 cards for $250 could be the cheapest way to get custom mechanical parts: https://www.youtube.com/watch?v=bkZkaT_P0Ck

Support Applied Science on Patreon https://www.patreon.com/AppliedScience
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Hacker News Stories and Comments

All the comments and stories posted to Hacker News that reference this video.
Nov 17, 2022 · 16 points, 2 comments · submitted by walterbell
aix1
Amazing work and such a detailed video. Kudos to the author.
pfdietz
Etched sheets like this have been used to make rocket engine thrust chambers. Holes for coolant channels are etched into the sheets, then the sheets are stacked and diffusion bonded together.
Nov 05, 2022 · 7 points, 1 comments · submitted by helsinkiandrew
jbay808
Anyone working in the hard-tech sector eventually hits the point where clever ideas alone aren't enough to make progress, and you need something made that seemingly is beyond the reach of even an advanced and well-funded prototyping facility. You know that the part you want is makeable; you know similar parts are found in even mass-produced consumer equipment (eg. inkjet printer nozzles), and yet even with a sizeable budget it's hard to find anyone who can make what you need to even test your idea without months of lead time at the minimum.

That's why Applied Science's channel is absolutely fantastic. It's amazing how he elegantly pulls centuries of know-how together (along with an eagerness to get his hands dirty) to make just about anything that's within the reach of today's high technology, in what appears to be a garage. And makes it look easy.

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