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Bespoke one-part filters
Bespoke one-part filters outperform traditional types Bespoke single-part filters for a diverse range of applications can be cost-effectively produced using Photo Electro Forming (PEF) and Photo Chemical Machining (PCM).
Dorset-based Tecan can produce customised metal filters in a single manufacturing process. Unlike conventional wire-woven products, single-part filters do not have cross-over areas. This brings a range of benefits, including the elimination of contamination due to trapped debris, no de-lamination at the edges, consistent cross-sectional thickness, and consistently accurate aperture shapes and sizes.
The processes allow both simple and complex designs to be realised; apertures and matrices of varying shapes and sizes, with single or multi-level planes, can be produced. A filter could have a small number of highly-accurate and extremely fine apertures, or be so tiny that many millions feature on a single part, each one, for example, as small as 3 microns across.
Tecan’s filters are burr and stress-free, with feature sizes and tolerances to suit individual application requirements. Various surface textures and finishes are also possible, including bright, semi-bright, matt, brushed, and smooth.
The company ensures the individual part is produced cost-effectively from the PEF or PCM process, or a combination of the two, to optimise its required performance characteristics. A recent example is a one-part filter manufactured from a single piece of stainless steel with apertures created using Photo Chemical Machining, which has replaced a wire-woven system in an advanced air-conditioning application. Easy cleaning and long operational life are resultant advantages of Tecan’s technology.
Advances in photo-resist technology enable the production of three-dimensional parts where ‘holes’ and ‘lands’ can be produced with up to 10:1 aspect ratios. This offers particularly beneficial strength and size ratios where very fine features can be produced with both great accuracy and mechanical strength, critical for the production of high-strength durable parts with fine-featured apertures and coplanar rigidity.