Photo Chemical Etched Encoder Discs with 0.05mm-0.4mm for Aerospace & Optical Systems

Photo Chemical Etched Encoder Discs with 0.05mm-0.4mm for Aerospace & Optical Systems

Product Overview
Encoder discs are critical parts in motion control and positioning systems, converting rotational or linear movement into precise digital signals. At Xinhaisen, we specialize in manufacturing high-precision metal encoder discs using advanced chemical etching technology. Our discs ensure exceptional accuracy, reliability, and durability for demanding applications across various industries.

Manufacturing Process
Our encoder discs are produced through a state-of-the-art precision chemical etching process. This involves:

• Material Selection & Cleaning: Choosing high-quality metal alloys (e.g., stainless steel, copper, beryllium copper, aluminum) and preparing surfaces.

• Photolithography: Applying a photoresist layer and using a high-precision photomask to transfer the disc pattern.

• Chemical Etching: Using controlled etchants to precisely remove unprotected metal, forming clean, burr-free patterns and apertures.

• Stripping & Cleaning: Removing residual photoresist and thoroughly cleaning the components.

• Post-Processing: Applying optional treatments such as blackening, plating, or passivation.

• Quality Inspection: Conducting 100% dimensional verification and visual inspection under microscopes to ensure absolute compliance.

Product Features

• Ultra-High Precision: Achieves extremely fine geometries with tight tolerances, critical for accurate signal generation.

• Burr-Free & Stress-Free: The etching process produces smooth edges without mechanical stresses, ensuring consistent performance and no magnetic deformation.

• Excellent Consistency: Batch-to-batch uniformity with reliable repeatability for every disc.

• Rapid Prototyping & Production: Quick turnaround from design to finished product, suitable for both R&D and high-volume orders.

• Material Versatility: Capable of processing various metals to meet specific mechanical, magnetic, or environmental requirements.

• Custom Design Friendly: Easily accommodates complex patterns, custom geometries, and unique sector arrangements without costly tooling.

Product Specifications

Product Applications
Encoder discs are essential in systems requiring precise speed, position, or angle feedback, including:

• Industrial Automation: Servo motors, CNC machines, robotics, rotary encoders.

• Optical & Medical Equipment: Scanners, analyzers, surgical devices, imaging systems.

• Aerospace & Defense: Guidance systems, instrumentation, avionics.

• Automotive & Transportation: ABS sensors, throttle position sensors, advanced driver-assistance systems (ADAS).

• Consumer Electronics: Printers, copiers, high-fidelity audio equipment.

Our Advantages

• Precision Experts: We excel in micro-etching with capabilities down to micron-level features, ensuring your discs meet the highest accuracy standards.

• Speed & Scalability: We combine fast response and prototyping with robust capacity for large-scale, on-demand production.

• Integrated Service: Full support from material selection and DFM (Design for Manufacturability) advice to finishing and quality control.

• Proven Reputation: Recognized by our clients for high quality, reliability, and exceptional customer service in the precision etching field.

• Technical Partnership: We work closely with customers to optimize designs for performance and manufacturability.

FAQ
Q: What file format do you require for the encoder disc design?
A: We prefer vector-based formats such as .DXF, .DWG, or .AI for optimal accuracy. Gerber files are also acceptable.

Q: Can you produce absolute encoder patterns?
A: Yes, our process is ideal for both incremental and complex absolute encoder patterns, including high-density codes.

Q: What is your typical lead time?
A: Prototypes can be delivered in as little as 5-7 days. Production lead times depend on order volume and complexity, which we will confirm upon project review.

Q: Do you offer different optical properties (e.g., high contrast)?
A: Yes, we provide various surface treatments like optical blackening or chrome plating to enhance contrast for optical sensor reading.

Q: What quality control measures are in place?
A: Every batch undergoes strict inspection using optical measuring systems and microscopy to verify critical dimensions, pattern accuracy, and surface quality against your specifications.

Welcome to contact us at any time!