Custom Lead Frames
Precision Photo Etched Lead Frames for
Electrical Applications Since 1964
Etchit manufactures custom lead frames and precision electrical contact components using photochemical machining (PCM). Designed and manufactured to customer specifications, lead frames can be produced in a variety of configurations to meet the electrical, dimensional, and performance requirements of the finished assembly. Lead frames and similar etched electrical components are commonly used to create electrical connections within an assembly and may provide contact points for soldering or other electrical connection methods. Designs can vary significantly depending on the application. Etchit manufactures custom lead frame configurations based on your drawings and specifications.
Lead Frame Applications Across Demanding Industries
Lead frames and precision etched electrical components are used across a wide range of industries, including aerospace and defense, automotive, medical, semiconductor, telecommunications, industrial electronics, and consumer electronics. Depending on the application, these components may be incorporated into semiconductor packages, sensors, electrical assemblies, control systems, communications equipment, and other precision electronic devices.
Etchit has extensive experience supplying precision etched components to demanding industries, including aerospace and defense, where dimensional consistency, material integrity, and reliable manufacturing processes are especially important. Our photochemical etching process is well suited for producing detailed lead frame geometries without introducing the mechanical stresses or heat-affected zones associated with some conventional manufacturing processes.
Why Use Photochemical Etching for Lead Frames?
Lead frames often incorporate thin materials, small features, closely spaced contacts, and intricate geometries. Photochemical machining provides an effective way to manufacture these features while maintaining dimensional consistency.
Benefits of using photochemical etching for custom lead frames include:
- Burr-Free Edges: Chemical etching removes material without creating the burrs associated with many mechanical cutting processes.
- No Heat-Affected Zones: Because the material is chemically removed rather than thermally cut, the process does not introduce heat-related distortion.
- Complex Geometries: Intricate patterns, openings, contact points, and other detailed features can be incorporated into a single component.
- Low-Cost Tooling: Phototooling eliminates the need for expensive hard dies and conventional tooling.
- Easy Design Changes: Phototools can be modified more quickly and economically when dimensions or configurations change.
- Prototype to Production: The same basic process can be used for prototypes, design iterations, and ongoing production quantities.
- Consistent Repeatability: Photochemical machining provides a controlled process for producing repeatable components across production runs.
Custom Materials & Configurations
Every application is different. Etchit works from customer-supplied drawings and specifications to manufacture lead frames in the geometry and material required for the project.
Our photochemical machining capabilities include a variety of commercially available metals and alloys, including:
- Kovar
- Copper
- Beryllium copper
- Brass
- Phosphor bronze
- Nickel and nickel silver
- Stainless steel
- Cold rolled steel
- 17-7 PH
- Additional materials upon request
Etchit can also coordinate secondary operations such as forming and bending, plating, passivation, and heat treating when required by the application.
From Prototype to Production
One of the key advantages of photochemical machining is its flexibility. Since the process relies on photographic tooling rather than expensive hard tooling, multiple lead frame versions or design iterations can be evaluated without the cost associated with creating a new stamping die for every change.
Whether you need to evaluate a new lead frame design, refine an existing component, or manufacture production quantities, Etchit can work from your drawings to develop a manufacturing approach that meets your project’s requirements.
Experience You Can Depend On
Etchit has specialized in photochemical machining since 1964, manufacturing thousands of custom precision metal component designs for customers across demanding industries.
Our team understands the importance of precision when manufacturing thin metal electrical components and works closely with customers to ensure parts are manufactured according to their drawings and specifications.
Request a Quote for Custom Lead Frames
Need a custom lead frame or precision electrical contact component? Send us your drawing or specifications and let Etchit help determine whether photochemical machining is the right manufacturing process for your application.