PHOTO ETCHING BRASS Jerry Gilland Boulder Model Railroad Club Aug. 22, 2013

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1 PHOTO ETCHING BRASS Jerry Gilland Boulder Model Railroad Club Aug. 22, 2013

2 Big Boy Running Gear All Brass Etched Nickel Plated Note Surface Relief

3 Riverboat Connecting Rod Brass Etched

4 Joseph Henry Riverboat Small Brass Parts Deck Railing Decorative Gingerbread Note: Hole Size = 0.015

5 Photo Etching Process Basics We are Etching Sheet Brass Some options: Pros Cons Single Side Etching Simpler Artwork Double Side Etching Mask 2 nd Side Anyway 2 x Faster Etching More Complex Artwork Less Undercutting Need Precise Alignment Allows Surface Relief! Multiple Step Etching Beyond the Scope of this Presentation! Recommendation Double Sided!

6 Photo Etching Process A hypothetical part Illustrating Surface Relief Step 1 Step 2 Brass Sheet Ultra Clean! Thickness Exaggerated Photo-resist sheet Laminate Photo-resist sheet on both sides

7 PREPARING THE ARTWORK White (Transparent) is the material that remains Black is the material that is etched away Top Side Bottom Side Retaining Tab

8 EXPOSING THE PHOTO-RESIST UV Light Photo Mask Glass Sheet Brass Photo Resist Exposed (hardened) Unexposed (soft)

9 DEVELOPING PHOTO-RESIST Exposed Plate. Exposed is hardened & acid resistant Developed Plate. Un-exposed is washed away

10 ETCHING PROCESS Partially Etched Fully Etched Photo-resist Removed Finished Part Scrap

11 PHOTO ETCHING PROCEDURE Materials/Equipment Needed Etching Acid Developing Solution Etching Tank (acid resistant) Photoresist Sheet (or liquid) Transparency Film Inkjet Film for Inkjet Printer Laser Film for Laser Printer Laminating Machine, or Capability Misc. Developing and Rinsing Containers

12 Recommendations! Purchase Micro-Mark Kit Page 20 of Summer Catalog - $108 Work in a Ventilated Work Area (You are working with toxic materials!)

13 Preparing the Artwork CAD works great (But we all don t have one) Maybe you have more graphics capability than you think! Try MS Word All Recent Versions Have Same Basic Capability Examples here are from Word 7

14 Preparing the Artwork Make oversize. Reduce print for photo mask Minimize border black Wastes etchant Remember - Black is etched away White is protected. Design in non-white Convert to White on Black when finished Print on Matte side of transparency film

15 Using MS Word Graphics Insert/Shapes Manipulate Shapes Fill Color & Border Rotate & Distort

16 Some Actual Artwork (From MS Word) Big Boy Fire Box Big Boy Valve Wheels Big Boy Cow Catcher

17 MS Word Demo

18 Make Decals Decal Paper Page 10 Summer 2013 Micro-Mark Using Word Art in MS Word

19 Artwork Printing Make oversize on MS Word Use Printer reduction for Desired Size Print on Transparency Film (rough side) Use Photo Paper setting (Some experimenting required) Tape to glass/plastic sheet (if double sided, align with bright light)

20 Brass Preparation Can cut with scissors. Must be ultra clean! Remove all oxide with polishing pad in kit. Or very fine emery cloth. Water should not bead on surface.

21 Brass Preparation (cont.) Photoresist film has protective sheet both sides In subdued light: Cut two pieces of photoresist film slightly oversize Peel protective sheet from concave side Scotch tape on corner Position, open side down, on wet brass Squeegee out excess water Repeat for other side

22 Laminating Must tightly heat bond photoresist to brass. OK Iron, set to medium Press between papers Some experimenting required!! Better Use Laminator provided with Micro-Mark kit Between special paper provided Two passes

23 Prepare for Exposure Place brass between front/back art Printed side to brass! Clamp tightly between two glass/plastic plates Note scrap of photoresist film included

24 Exposing Photoresist Too Much black areas get a little exposure Too little clear areas don t get fully exposed Slow, but sure 60 watt incandescent, 4 inches from specimen 10 minutes per side Slightly poorer resolution (diffuse source) Fast, but tricky Direct Sunlight 10 seconds per side at noon on clear, bright day 30 seconds at 3:00 pm on hazy day Test strip turns blue

25 Properly Exposed Example Test strip Note clamp shadow Exposed plate before etching

26 Developing The Exposed Plate Developing Solution is Sodium Hydroxide 1 part Micro-Mark PRO-ETCH to 5 parts water Remove remaining protective sheet on photoresist both sides Place in developer solution agitate/brush for about 20 seconds Turn over and repeat Remove, brush with soft brush, rinse and test Scrape un-exposed area with knife point Should see only clean brass Repeat, 10 seconds at a time, if necessary. Note: Developing is faster in warm solution!

27 ETCHANT OPTIONS Ferric Chloride Comes with Micro-Mark Kit Fast 10 to 15 minutes Messy Stains everything it touches. Hard to Find Locally Opaque Can t see etching progress Must remove & rinse to check progress

28 ETCHANT OPTIONS Home Made 2 Parts Medical Grade Hydrogen Peroxide (3%) 1 Part Muriatic Acid (30%) Shorter Life 5 to 10 Small Parts Cleaner But still an acid! Locally Available Transparent Can see progress Inexpensive _ $.50/3 oz batch

29 ETCHING TECHNIQUES Use NO metal containers or tools! Use ONLY glass or plastic (test first) containers and tools. Micro-Mark Kit Vertical Tank with Aquarium Bubbler and Ferric Chloride Trouble with non-uniform etching Have to remove part and rinse to see progress

30 ETCHING TECHNIQUES Kitchen Raid Glass Cake Pan with home made etchant Brush away oxide regularly non metal brush Turn over every 3 4 minutes Can see progress without removing/rinsing Home Made Tools

31 Etching Problems Under-developed photoresist Areas to be etched should turn gray/matte within seconds. If not, remove, rinse and develop further Non-uniform etching Above, or inadequate agitation/brushing Undercutting with thick brass Etch from both sides Over etching Developed areas start to etch fuzzy edges Too late to fix!

32 Etching Problems (Cont.) Etching Solution Worn Out Excessive etching time (> 1 hour) Warming solution slightly helps Life of Muriatic Acid solution For a three ounce batch Cost = 50 cents! Typically 5 to 10 of my parts Calculated at about 4 sq. in. of Brass sheet I.e. about 0.02 cu in of brass. Doesn t store well Degrades over night Toss it and start over tomorrow! Life of Ferric Chloride solution??? Longer Stores OK.

33 Final Steps Remove exposed photoresist Soak in a small amount of un-diluted developer solution Developer & Etching Solution Disposition I don t worry about saving it. It is inexpensive. Developer Just pour it down the sink and flush well Etchant Don t pour it down the sink! It will eat your plumbing. Pour in bicarbonate of soda until it stops bubbling. It is now safe to pour it down the drain. Note: Do this in a ventilated area. Hydrogen gas is given off in this process.

34 REMEMBER! You are working with powerful, toxic materials Ventilation is required Fumes are toxic Wear rubber/latex gloves Acids will cause skin irritations or burns Wear safety goggles Modeling can be severely limited when blind!

35 For more Info For a copy of this Power Point presentation. Just me, or fill out the sign-up sheet With questions Just , or call me Contact Info gillandjj@comcast.net

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