Chemical Etching

Chemical etching removes material with controlled chemical reactions to create permanent, low-stress surface markings or textures with fine detail and minimal distortion.

Overview

Chemical etching (acid etching) uses a patterned mask (resist) and an etchant to selectively dissolve the surface of a metal. It creates permanent text, logos, scales, matte textures, or light-relief features without mechanical forces, so thin parts and delicate geometries see minimal distortion. Typical depths range from very shallow “frost” marks to moderate relief, depending on alloy, chemistry, and exposure time.

Choose chemical etching when you need consistent, non-contact marking across batches, especially on hardened or formed parts where stamping or engraving could cause stress, burrs, or warpage. It scales well for multiple identical marks or panels and can cover large areas uniformly.

Tradeoffs: depth control is limited compared to machining, edges can show undercut from isotropic etch, and masking/fixturing adds setup cost. Not all alloys etch cleanly, and tight feature spacing or very deep etches increase variability and lead time.

Common Materials

  • Stainless steel 304
  • Stainless steel 316
  • Aluminum 6061
  • Brass C260
  • Copper C110
  • Titanium Grade 2

Tolerances

±0.003"

Applications

  • Instrument panel scales and nameplates
  • Stainless equipment tags and asset labels
  • Decorative brushed/matte textures on visible hardware
  • Identification marking on medical tools
  • Control knobs and dial faces
  • Anti-glare texture on optical/mechanical housings

When to Choose Chemical Etching

Chemical etching fits parts needing permanent, high-contrast markings or uniform textures with minimal mechanical stress on thin or finished components. It works best when artwork can be masked cleanly and depth requirements are modest and repeatable across many parts or large surface areas.

vs Media Blasting

Choose chemical etching when you need crisp, repeatable graphics, small text, or tight layout control; blasting tends to soften edges and vary with operator technique. Chemical etching also enables selective marking without roughening surrounding areas if masking is well controlled.

vs Laser Etching/Engraving

Choose chemical etching when heat effects (HAZ, discoloration, microcracking) or reflectivity make laser results inconsistent, or when you need uniform texture over a large area. Laser is often faster for one-offs and deep marks, but chemical etching can be more consistent across batches and complex surfaces.

vs Mechanical Engraving (CNC/rotary)

Choose chemical etching when you need non-contact marking on thin parts or cosmetic surfaces where tool marks and burrs are unacceptable. Mechanical engraving wins for precise depth targets and sharp bottom geometry, but it adds cutting forces and fixturing complexity.

vs Pad Printing / Ink Marking

Choose chemical etching when markings must survive solvents, abrasion, and high temperatures without maintenance. Ink methods are faster and cheaper for low-durability labeling, but they can wear or lift on textured or oily surfaces.

Design Considerations

  • Specify required mark depth and acceptable depth range; shallow cosmetic etches are more consistent than deep relief
  • Keep minimum line widths and spacing realistic for masking; very fine features increase undercut and variability
  • Avoid demanding perfectly sharp corners; isotropic etching rounds edges and widens features with depth
  • Call out surface condition before etch (finish, coatings, passivation, anodize) since it affects mask adhesion and contrast
  • Provide vector artwork (DXF/AI/SVG) with font outlines and clear polarity (etch vs protect) to reduce interpretation errors
  • Define which surfaces must remain untouched and how parts will be fixtured/masked to prevent bleed and edge creep