It is well known that rapid production of prototype plastic parts is common engineering practice, it is less well known that the same applies for thin gauge metal components.

While high volume manufacture of thin metal parts usually take the press/progression tool route, this is not a viable option for prototype or rapid new product introduction (NPI) applications.
Having the ability to produce mouldings within hours is obviously wasted if the manufacturing lead-time allied for metal work is weeks. A solution to the problem is to blank the profile first followed by subsequent forming and finishing operations.
Although blanking can be achieved by a variety of methods chemical etching also known as photo chemical machining (PCM), is often overlooked. This versatile manufacturing process is often wrongly considered only suitable for flat parts in high volumes.
This may of have been the case 40 years ago, however improvements in the processing machinery and CAD technology have made prototype and small batches a viable proposition irrespective of complexity. By taking the PCM blanking option, form tools are less complicated and therefore much quicker to manufacture.
In many cases modular or universal form tooling can be utilised, resulting in only simple blade or location stop manufacture being required.
By leaving the blanks attached to the processing sheet with small tabs, subsequent plating operations can be undertaken without the need to wire individual components, or risk distortion by barrel processing.
In addition to speed of manufacture the PCM process also offers the ability to add identification marks and 'half etch' fold lines without additional cost. PCM gives another advantage over other blanking methods in that it is a completely burr and stress free process, which unlike laser does not effect localised temper of the metal.

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Qualitetch Components Ltd is based in Peterborough, Cambridgeshire, UK. wwwqualitetch.co.uk