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Why is mechanical milling taking over chemical etchingfor PCB prototyping?

Mechanical milling offers significant advantages compared to chemical etching, whether in terms of environmental responsibility, operating costs or manufacturing quality when it comes to prototyping.

1. A more environmentally-friendly process

• Elimination of toxic chemicals

  Chemical etching requires the use of acids and complex chemical solutions, presenting environmental and health risks. Transportation, storage and handling are subject to complex and costly regulatory restrictions. Mechanical milling eliminates these restrictions.

• Reduction of hazardous waste

  Used chemical baths must be treated before disposal, which generates both costs and strict regulatory obligations. Mechanical milling significantly reduces this waste.

• Improved carbon footprint

  Fewer chemicals mean reduced transport and waste management, contributing to more sustainable production.

2. A more economical process in the long term

• Fewer consumables

  Mechanical milling uses reusable tools and does not require the regular purchase of chemicals.

• Lower waste processing costs

  Chemical baths need to be regularly replaced and reprocessed, which generates additional costs.

• Less maintenance and regulatory restrictions

  Maintenance of mechanical pcb prototyping equipment is simpler and does not require compliance with hazardous chemical management regulations.

3. Greater quality and precision

• Process control and repeatability

  Mechanical or laser milling process for pcb structuring ensures constant, reproducible precision without depending on chemical variations in the baths. Today's mechanicals and laser pcb prototyping systems have reached a level of precision that can match or even surpass the capabilities of chemical etching machines for printed circuits.

• No over-/under-etching of copper

  Mechanical milling guarantees clean, precise processing. Chemical etching can lead to engraving defects due to deterioration of the photosensitive resin during storage or deviations in the process (over- or under-exposure, over-development, etc.).

• Adaptability to new materials

  Some materials react poorly to chemicals, whereas mechanical or laser process can be adapted to a wide range of substrates.

4. Ergonomics and simplicity

• Less training required and quicker to implement

  Unlike handling hazardous chemicals, mechanical engraving requires simplified safety training for operators. In addition, the photolithography etching process (chemical etching) is more complex because it requires more steps and therefore also more skills and therefore also more time to assimilate, master and implement. Mechanical engraving is quick and easy to learn, requiring just one computer-controlled machine.

• A healthier working environment

  Elimination of the risks associated with chemical fumes and dangerous handling.

• Easier regulatory compliance

  fewer constraints on the storage, use and disposal of hazardous substances.

The transition to mechanical process represents an opportunity for technological and environmental improvement while reducing operating costs.

It guarantees cleaner, safer and more accurate production, while simplifying process management.

Faced with all the risks and regulatory constraints and the complexity of the chemical etching process, mechanical (or laser) pcb structuring process offers a simple, cost-effective and high-performance alternative for retaining in-house control over the production of prototypes.