How To Make Deep Etches
Deep etches are made with heavy duty power units designed
for this purpose. The etch is made by using direct current
(dc) for long dwell periods. The longer the dwell, the
deeper the etch. As the etches become deeper, they tend
to become fuzzy at the edges due to the fact that the
current flow cannot be directed straight downward. The
appearance of the deep etch is improved by lightly polishing
it with crocus cloth.
In making deep etches, it is imperative that a deep etch
pad be used. Deep etch pads are available for bench markers,
hand markers and marker cartridges. Best results are usually
obtained with the marker cartridges.
A deep etch pad unlike a normal marking pad, consists of
a highly fibrous material. The fibers of this material, with
slight pressure, will push through the fibers of the stencil,
allowing current to flow freely and easily so that the metal
is removed at a rapid rate. Of course, it is necessary for
the deep etch pad to be saturated with electrolyte at all
times, the electrolyte being a good conductor. The presence
of the deep etch pad and the excess electrolyte keeps the
stencil cool and increases its life.
In making deep etches, it should be remembered that a very
light pressure should be used. Usually, the pressure of the
marker itself is sufficient. Excess pressure pushes the electrolyte
out, drying the pad and destroying the stencil.
In general a heavy duty power unit will make deep etches
in the area of .0005 inches deep in less than ten seconds.
If repeatable depth is necessary, use a power unit with a
timer thus allowing the current to flow the exact amount
each time.
Where deep etches from .0005 inches deep to .005 inches are
required, it is advisable to use a pulsating type power unit
with a timer so that the current flow can automatically be
cut off and on, thus allowing the electrolyte to flow back
into the etch.
The deep etch power unit creates such heat after six seconds
dwell time that unless the current flow is broken up by a
pulsator, the stencil will burn up and the pad will dry up
and the desired results may never be obtained.
It is also advisable when considering deep etch to review
specifications and needs. Often a deep etch is requested
to the depth of a steel stamp. Such depth is costly and usually
not needed as a depth of .0005 inches is very deep and very
hard to wear off. Usually when .0005 inches is worn off the
part itself is worn out and ready for replacement.
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