Precision Thin Metal Fine Mesh Screens

.002 Inches Thin Metal Fine Mesh Screen in Stainless Steel

Custom made, stainless steel, 0.002 inches thin metal, with 0.002 inches web thickness, precision fine mesh screen.

Contact E-FAB for precision fine mesh screen information or sales quote.

Round ScreensClick on images above for close-up views of thin metal screens.

E-FAB builds all types of screens, using a wide variety of metals and alloys. Any shaped screen for your needs. Need a unique shaped screen, for a unique application, bent, or formed, or even integrated into another metal piece? No problem. Contact E-FAB today for all your fine screen needs.

E-FAB provides photo etched and photo chemically machined products for a diverse group of industries and applications including: military, medical, dental, optical, NASA, PCB industries (rigid, flex, hybrid-flex, and rigid-flex printed circuit boards), aerospace products, communications, computers, electronic equipment, EMI technologies, hybrid circuits, Interconnect assemblies, laser, instrumentation, ordinance, power semiconductor, semiconductors, RFID microwave antenna, stacked memory arrays, interconnect modules, tactical, weapons systems, solar, and other high tech OEM companies on the leading edge of new technology development.

Contact E-FAB – Click Here for Screens Quote

Get started on your own OEM screen designs with E-FAB’s stainless steel screen mesh panels available in various mesh screen sizes. Simple to trace and cut out your unique screen designs (no special tools required).

E-FAB Micro Mesh Screens

Click on image to learn more about these screens that are designed for engineers and experimenters. Contact E-FAB today for more information.

Small Mesh Screen Sizing Chart for Pre-Built Screens

Custom Sizes (Web Thickness & Spacing) and Holes (Square, Hexagonal, Round and Others) are Also Available

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E-FAB Precision CNC Drilling and Routing Machine Operation

E-FAB’s precision flex circuits and thin metal parts drilling and routing machine in action video (view video below).

The following E-FAB video is of our drilling and routing machine in operation. Please read the details of the video below. The first half of the video shows the drilling mode and the second half (starting at the 2:40 mark), is the machine running in the routing mode. The video is showing a “first run.” E-FAB drills and routs in thin metal parts, flex circuits, and rigid flex circuit board applications. The CNC machine is a precision air bearing machine capable of both drilling and routing modes of operation. This is in addition to E-FAB’s precision photo chemical machining, photo etching, and chemical milling processes.

In the first part of the machine video, during the drilling mode, the machine is actually drilling very small holes into an entry material. Some of the larger holes can readily be seen in the panel, however many times the small holes on a circuit board or thin metal material are so small {.010 inches (0.254 mm) in diameter or smaller} that it is difficult to see them without holding the panel up to the light or using an eye loupe for detailed views.

This automated CNC machine is capable of very tight drilling accuracies and precision part dimensions when routing. With the built in vacuum pressure foot assembly for keeping thin parts solidly held in place and clean during the drilling and routing processes, the high speed air bearing spindle (with very little spindle runout) designed for drilling and routing tight tolerance parts, and the precision X, Y, and Z axis servo positioning systems for high positioning accuracy, E-FAB has the in house capabilities, using the CNC drilling and routing machine, to complement our photo etching and photo chemical machining (PCM) processes. It allows us to provide the best of both worlds solutions for our customers’ needs; very accurate fine line PCM processes and precision small hole drilling, along with detailed parts and item features precisely routed, which is above and beyond of what others in either the circuit board industry or the PCM industry can do for you. With E-FAB, our customers appreciate it that we do quite a number of processes that are manufacturing complementary [manufacturing, engineering, and design], extremely well.

Check out some of the thin metal parts and flex circuits manufactured by E-FAB.

Contact our sales and engineering staff to get a thin metal parts or flex circuit boards quote(s) today.

Contact E-FAB Sales and Engineering Today

Checkout E-FAB PCB stiffeners and busbars for your printed circuit board needs. E-FAB PCB stiffeners and busbars are designed to increase board rigidity, improve circuit components reliability, and strengthen PCBs for rugged environments such as for the military and other harsh environment usages.

E-FAB Circuit Board Stiffeners and Bus Bars

Click here for more info on PCB Stiffeners and Bus Bars

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Merry Christmas 2010 & Happy New Year 2011

E-FAB Christmas Party 2010

E-FAB

O What Fun We Had Photo Etching All The Way!

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Welcome to the New E-FAB Website Design

We are really excited about our new E-FAB website look and feel, and we think you will like it too! E-FAB can do what some in the industry feel is the impossible.

By-the-way, for our foreign language guests and readers, please use the translation button on the right side of the website to at least help you through the E-FAB website discovery process.

E-FAB Sculptured Flex Circuits

E-FAB Sculpted Flex Circuit and Scuptured Flex Circuit

To better understand the various industries that E-FAB serves is quite difficult to explain in one or two sentences. When we say that we serve a plethora of industries, we really do mean a lot of industries and many applications, too many to count, worlds apart, and out of this world (outer space applications). In fact, many of the applications and product developments that E-FAB has worked with in close conjunction with our commercial, military, and government clients, has pushed E-FAB to develop new fabrication and manufacturing techniques for various parts and engineering designs that were once thought impossible to build.

Take for example, aluminum flex circuits. You might ask, why in the world, would someone need an aluminum flex circuit? Well, these type of unique requests are not unusual at all, but are quite typical for our customers to request E-FAB to build what others can not. The reason E-FAB can build it, is because of our diverse photo chemical machining (PCM) capabilities and our proprietary processes that our engineers have developed over the years.

E-FAB Micro Bumps on Actual Part SizeE-FAB Micro Bump TechnologyAnother amazing example of one of E-FAB’s technological breakthroughs is our proprietary E-FAB Micro Bumps technology, which was developed for a customer’s special application requirements. Case in point, pardon the pun, a customer needed miniature contact points, ( to put this in visual perspective, see small actual part size on the top left) laid out in a certain grid patter (see magnified closeup picture on the right), and E-FAB was asked if we could build it for them. The answer was, “yes E-FAB can build it” and we did with great success! This micro bump technology is ideal for micro switch contact points and other applications for precision raised bumps on a diverse array of metals and alloys. Needless to say, the customer was extremely happy with the Micro bumps results. Click on the picture for more details about the E-FAB Micro Bumps technology.

What can E-FAB Manufacture, Fabricate, and Machine for you?

E-FAB can manufacture, fabricate, and micro machine just about anything related to thin metal parts and save you money too! Take a look at E-FAB’s banner header to give you a better idea of what we do. E-FAB has many stars that shine brightly in the world of technology, manufacturing, machining and fabrication. E-FAB’s manufacturing, engineering, and design support services are here to serve you. We take great pride in our customer service, and our sales and engineering folks are here to support your custom built parts from the early conceptual stages of a product’s design, all the way up to prototype and mass production of the finished parts.

E-FAB Photo Chemical Machining Precision Metal Parts

The list is equally endless as far as what E-FAB has manufactured over the years.

A sampling of items produced by E-FAB include: Space Fed Lens antennas, Space Borne etched antenna membranes, machined forming dies, formed contacts, micro milled and etched RFID tracker antenna fabrication geometries arrays, Teflon bonding of precision parts, Micro bumps, micro contacts, engineering change order products — flexible jumpers traces add-a-trace™, specialty FAB, flex circuits, PCB rigid-flex boards, leadframes, separators, connectors, interconnect interposers for stacked memory devices and other components, RF shields, power EMI and RFI shielding, electromagnetic shielding cages, lids, step lids for hybrid packages, screens, filter mesh screen, custom filters for fine particulates, EMI filter screens and RFI filter mesh screens, printed circuit board hardware components such as: heat sinks, PCB jumpers, shims, stiffeners, carriers, thermal layers, planes, frames, etc., direct bonded copper for high power applications, dielectric coated copper conductors, insulated contact, non-insulated contacts, precise manufacturing of specialized tooling, etched encoder disks and encoder strips large format and small formats, etched ultra precision metal scales, semiconductor lead frames, gimbals springs, precision washers, surface mount solder screening stencils, bus bars, actuator bands, miniature ornaments & decorative designs parts etching, model photo etching, etched septum filter inserts, complex shaped formed and bent thin metal widgets.

As you can see, E-FAB has the capabilities to do just about anything related to thin metal parts manufacturing, fabrication, and custom designs. Our multifaceted widgets category of precision thin metal parts is constantly growing. In fact, the list of proprietary widgets are too numerous to count nor could we even begin to share that with you here.

Some of the typical types of metals, alloys, and composite materials E-FAB has used in precision parts manufacturing include: thin metal parts made of copper, beryllium copper, brass, bronze, tin, nickel, nickel silver, molybdenum, steel, stainless steel, spring steels, Monel, aluminum, magnetic alloys, Duroid laminates, polyimides, Teflons, ceramic substrates, Kovar, and other common and exotic materials are all ideally suited to be fabricated using the E-FAB photo chemical machining, photo etching, and micro milling processes.

E-FAB invites you today to take a look around our new updated website. If you don’t see it here, it is probably because, the list is endless and was a simple oversight on our part. Contact E-FAB for a quote on your part designs, ideas, or just to ask a question or two.

Contact E-FAB – Click Here for Sales Quote
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E-FAB Microstrip Photo Etched Antennas

Photo Etch AntennasE-FAB is a photo etch, photo chemical machining, and micro chem milling manufacturer of microstrip antennas on various substrates such as Duroid laminates, polyimide, Kapton, Teflon, and ceramics.

FR4 epoxy fiberglass laminates have also been used but the Duroid laminates, polyimides, Teflons, and ceramic substrates typically have better electrical impedance, thermal, chemical, and mechanical properties than FR4 laminates. Antennas have been designed and built on substrate thicknesses from 5 thousandths to 60 thousandths (.127 MM to 1.52 MM) typically, with some antenna designers requesting thicknesses up to .250 inches (6.35 millimeters). These substrates are copper clad, single or double sided, with 1/4 oz., 1/2 oz., 1 oz., and 2 oz. copper typical. Double-sided substrates are typically used for microstrip antenna ground planes.

Once the photo etch process is completed, the etched antenna elements can then be electroplated with various metals or alloys such as tin nickel or gold plating. The plating process depends on the customer’s applications and antenna design requirements.

Flex Film Antennas

Flex-film polyimides, Kapton, and other polyimide flex substrates have also been used for a variety of photo etched antennas. E-FAB has built antennas using flex-films with thickness as thin as .001 inches (25 microns). See more information on E-FAB flex circuits.

Photo Etch vs. Printed Circuit Board Etching

The advantage of using E-FAB’s photo etch process compared to PCB manufacturers, is E-FAB can hold tighter tolerances than traditional printed circuit board shops. With E-FAB’s photo etch solution, we can etch a wide variety of metals and alloys. Circuit board shops are typically limited to the types of metals and substrates they will work with because of the PCB shops limited chemical etching solutions on hand. In fact, many PCB shops actually use E-FAB to build the parts for their customers when the design requirements dictate processes beyond that of the PCB shops’ abilities.

Antenna Fabrication Experience With E-FAB

Experience is another factor to consider when having reliable antennas manufactured. Most circuit board manufacturers have experience with FR4 but have very little if any experience at all when dealing with microstrip etched antennas. E-FAB has been building antennas since 1981 and is a preferred supplier for many industry leaders. E-FAB has built antennas for JPL, NASA, the military, and private sector companies and has antenna manufacturing experience with: cones, horns, helix, spirals, microstrips, patch, hybrid etched antenna arrays, phase array, fractals, micro, blade, miniature parabolics, rigid and flexible antennas.

Contact E-FAB for customer services, engineering assistance, or an antenna sales quote for your precision antennas today.

Contact E-FAB the Antenna Manufacturing Specialist
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Machine Shops – E-FAB Photo Chemical Machining Is For You and Your Customers Too

Machine shops and your company should be interested in E-FAB’s photo chemical milling, photochemical machining, and photo etching outside services.

Learn how E-FAB PCM save you and your customers time and money now!

Learn why you should use photo chemical machining, milling, and photo etching. The bottom line is E-FAB PhotoChemical Machining can save a machine shop and their customers time and money in a multitude of ways. Many times OEM customers have no idea about what processes are involved in the manufacturing or fabrication of metal parts, or the differences between electrochemical, photochemical, and CNC machining. They only know that they want quality parts machined to specifications, with on time delivery, and at the agreed upon pricing. They don’t care how a machine shop produces it, or the tooling involved, or even the degree of difficulty in the machining process because of the complexity of the metal parts designs. No — none of that really matters to the OEM customer. They just want to know; can you do it, and at what price?

Let’s say you are a full service machine shop with CNC turning (lathes), CNC milling machines, CNC laser cutting equipment, CNC waterjet cutting, and wire EDM (electrical discharge machining). Customers come to your place because you can do it all, right? Yes, you can do it all, but some of those parts are going to cost you more in time and labor by machining them in a traditional manner rather than what could be done using E-FAB’s photo chemical milling, photo etching, and photo chemical machining services.

Photo chemical milling, (PCM) photochemical machining, and photo etching are ideally suited for most metals and alloys that are less than .050″ in material thickness depending on which particular chemical process and part tolerances or metal types that are being chemically milled, machined, or etched. Read about the various photo chemical machining applications and the industries that use it.

Metal And Alloys Suited For Photo Chemical Machining

The machining of thin metal parts made of copper, beryllium copper, brass, bronze, tin, nickel, nickel silver, molybdenum, steel, stainless steel, spring steels, aluminum, magnetic alloys, and other common and exotic materials are all ideally suited to be fabricated using the photo chemical machining process.

Photo Chemical MachiningWhat are the photo chemical machining, milling, and photo etching benefits vs. traditional CNC milling & machining?

E-FAB PCM is an excellent alternative to traditional CNC machining operations. Thousands or millions of high precision parts can be manufactured at one time with substantially reduced tooling costs. Metal parts that are intricate in nature, with complex shapes and geometries, can easily be tooled up on a computer using CAD/CAM software and outputting photo-tooling which minimizes expensive CNC mechanical and manual operations costs.

Finished metal parts can be delivered quickly. Parts requiring tighter tolerances can be easily stepped and repeated on larger panel sizes with very high parts to panel density ratios. This substantially increases the yield ratio and decreases the material waste.

Engineering modifications can be done quickly and conveniently using CAD/CAM software. E-FAB PCM allows the designer and engineer to minimize costs and significantly reduce the turnaround time involved with prototypes and significantly improve the engineering and design, to prototype, to production time frame.

The E-FAB PCM process maintains surface quality without producing surface burring or tool marks as compared to CNC machining. Metal properties and structure integrity of the alloys are maintained with the PCM process. Alloys such as: Kovar, nickel, brass, beryllium, copper, stainless steel, aluminum, and others are included for PCM fabrication by E-FAB.

Thin metal parts can be formed and bent into complex shapes. Etched bend lines can be included into the part design so as to provide excellent metal facets for forming, shaping, and bending the parts into the final fabricated part design.

Traditionally, CNC machining and CNC milling has difficulty machining thin metal parts. With E-FAB PCM services and our engineering support team, a machine shop can solve the complex thin metal parts challenges using the PCM solution, at a fraction of a machine shop’s manufacturing cost.

E-FAB also provides engineering, manufacturing, design, and technical support services for all types of applications for military, defense, and in private sector industries.

Contact E-FAB for a quote on your thin metal parts jobs. Have a question? No problem; unique applications and designs are welcome.

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Etched Septum Filter Inserts

An Ideal Application For Photo Chemical Machining, PCM, Is In The Microwave Industry

Engineering design software and resources can be found at www.engineers.com

E-FAB can help you with the manufacturing processes used in Septum Filter Inserts, E-Plane, E Planes, and Waveguide Filters. E-FAB has the PCM experience in etching various microwave and antenna components. Call or write E-FAB today for price quote and/or manufacturing engineering support for your precision parts.

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E-FAB 2006 Christmas Party

Everyone enjoyed themselves at the 2006 Christmas Party

A time to relax, have fun, enjoy the company, and have some great food.

View the E-FAB Slide Show.

E-FAB provides Photo Chemical Machining, Photo Etching, and Photochemical Milling for a wide variety of industries. The process can very precisely etch lines and spaces all all types of of metals and alloys ranging from: kovar, nickel, brass, beryllium, copper, stainless steel, aluminum, and others. Ideal for thin metal parts fabrication. Parts can also be bent into complex shapes. Sizes of the parts range from miniature to macro. Micro antennas and space fed lens antennas are just a couple of products that are ideally suited for production through the PCM process.

Here is an excellent overview of Photo Chemical Machining.

Contact E-FAB for all your photo chemical machining, etching, and precision chem milling today.

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Large Format Photo Etched Antennas

JPL Antenna Element Pictured Below Is for a KA-Band Antenna
Antenna element is one of 16 strips that JPL assembles into a 3.5 meter diameter Space Borne antenna system.
Antenna Element for Large Format Antennas
E-FAB has developed a process by which tight tolerances can be held in a large format photo etched pattern. Chair is displayed as a reference to provide size comparisons between the etched antenna strip shown and the surrounding surface area. Take a close look at the close up inset image for a better idea of the finished pattern size and product dimensions.

For more information on photo chemical machining of etched antenna patterns contact E-FAB today. Our experienced sales department and expert engineers can help with your product designs today.

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Precision Mil Spec PCM Manufacturing & Fabrication

E-FAB PCM and Photo Etching
Precision Mil Spec PCM and Photo Chemical Etching

E-FAB Precision Thin Metal Parts Manufacturing

Sure we can do the simple etching and photo chemical machining fabrication, but our real strength lies in manufacturing close tolerance parts for a plethora of industries (including Defense and Commercial sectors). We manufacture everything from fabricating the precision miniature thin metal parts, to the macro size multifaceted – large format; with extended lengths from 36 inches, 48 inches, or more. E-FAB is continuously developing manufacturing and proprietary processes that enable precision etching of large format substrates 60″ long or longer. Currently we are etching 72″ long antenna geometry patterns for NASA. We have developed proprietary processes which enables us to hold the close tolerances during fabrication and manufacture of thin metal parts along with other precision specialty flexible circuits than what can be achieved above and beyond what other manufacturers or manufacturing processes can do.

Also check out the 44″ special application precision encoder strips.

Another area which is very interesting, is our unique micro bump micro contact technology; which has many unique applications for the OEM producers.  For example, E-FAB’s micro bump technology can be applied to various engineered devices from precision micro switches and contact points, to capacitance sensitive circuits.

Be sure to check us out today to see how our E-FAB PCM process technology integration can benefit you and your requirements for precision manufactured products. Talk to our engineers about your special applications and will be glad to assist in all aspects of your product’s development. Take a look at E-FAB today. We think you will be amazed at what we can do for you.

Checkout E-FAB precision PCM thin metal parts manufacturing and fabrication today.

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