Fotofab

• Manufactures custom precision metal components using photochemical machining (chemical etching)
• Focus on small, thin metal parts with intricate, high-precision features
• Supports quick-turn prototypes, short-run, and full production runs

Core Processes and Services

• Photochemical machining (chemical etching) of flat sheet metal
• Precision metal forming and bending for small sheet metal parts
• Metal finishing options to deliver ready-to-use parts, including (but not limited to):
• Plating
• Blackening and black oxide
• Electropolishing
• Painting
• Passivation
• Tumbling
• Reaming
• Diffusion bonding – joining layers of sheet metal with heat and pressure
• Rapid prototyping of precision metal parts
• Custom packaging options to protect parts in transit

Markets and Applications

Fotofab manufactures precision metal parts primarily for:

• Aerospace
• Military and defense
• Medical
• Medical implantable components
• Energy and alternative energy
• Electronics
• Telecommunications
• Industrial equipment
• Photonics and optics
• Automotive
• Decorative metal components

Materials

• Etches both standard and exotic metals
• Supports non-corrosive and biocompatible metals
• Works only with flat metal sheets (no tubes or 3D surfaces)
• All metals are sourced from the United States, with a small exception for some aluminum

For a full list of metals Fotofab can etch, customers should refer to the "Metals We Etch" information on the main website or contact Fotofab directly.

Typical Part Characteristics

• Intricate, burr-free features produced without mechanical stress or extreme heat
• Minimum and maximum metal thicknesses (general guide):
• Works with metals from approximately 0.0002" (0.005 mm) to 0.062" (1.57 mm)
• General sheet size guideline:
• Up to about 24" x 36" (60.96 cm x 91.44 cm)

Specific tolerances, feature sizes, and design rules depend on material and part geometry and should be confirmed with Fotofab engineering.

Location and Manufacturing

• All Fotofab parts are manufactured in Chicago, Illinois, USA
• Main plant: Chicago's Northwest Side, housing multiple etching machines and CAE/CAD capabilities
• Tooling, forming, and stamping facility: Elk Grove Village, Illinois, near Chicago O'Hare Airport

How to Engage Fotofab

• Engineers typically send drawings and requirements to receive:
• Material and design guidance
• Quotation for prototypes or production runs
• Fotofab supports customers from initial design and material selection through prototype and into production.

• Fotofab uses chemical etching, also called Photo Chemical Machining (PCM).
• The process uses chemicals (such as ferric chloride or hydrofluoric solutions, depending on the metal) to remove unwanted metal.
• The metal's natural properties are not altered:
• No extreme heat
• No mechanical stress as with stamping or some laser cutting methods
• Fotofab etches only flat metal sheets and can form parts after etching is complete.

Location of Manufacturing

• All Fotofab parts are manufactured in Chicago, Illinois, USA.

Plant Tours and Samples

• Plant tours are available by appointment.
• Samples can be provided on request.
• Both can be arranged by contacting Fotofab directly (phone or website contact form).

Lead Times

• Standard turnaround time for most orders is about 10 business days.
• Expedited options are offered for a premium on many orders:
• 5-day, 3-day, and same-day delivery (availability depends on part complexity and requirements).

Ordering, Quotes, and Payment

• Requesting a quote (RFQ):
• Submit online via the Request a Quote form
• Email drawings and requirements to sales@fotofab.com
• Fax to (773) 463-3387
• Minimum order quantity:
• Typically two sheets of material; overall minimum lot cost depends on metal type, thickness, secondary operations, and packaging.
• Accepted drawing file formats:
• STEP
• DXF
• DWG
• X_T
• Payment methods:
• Visa
• MasterCard
• American Express (AMEX)
• U.S. government credit cards

Dimensions, Tolerances, and Design Guidelines

• Metal thickness range (general guide):
• From approximately 0.0002" (0.005 mm) up to 0.062" (1.57 mm)
• Maximum sheet size (general guide):
• About 24" x 36" (60.96 cm x 91.44 cm)
• Hole and slot sizes (rules of thumb):
• Smallest practical hole or slot width is about 1.2× the metal thickness
• Minimum practical diameter or slot width can be as small as 90% of the metal thickness, depending on application
• Tolerances (typical guidelines):
• Dimensional tolerances often follow about ±10% of the metal thickness
• Depth-of-etch tolerance can be as low as about ±0.0005" (0.0127 mm)
• Minimum feature sizes:
• Minimum bar width is generally about 90% of the material thickness

These values are general guidelines. Exact capabilities for a specific part, material, or application should be confirmed with Fotofab engineering.

Tabs, Burrs, and Part Removal

• Parts are usually laid out on a sheet and held in place with small tabs during etching.
• When parts are detached from the sheet, small burrs can remain at tab locations.
• Customers may specify preferred or prohibited tab locations on their drawings.
• "Drop out" parts (no tabs) can be produced, but this may affect tolerances and yield.

Packaging Options

• Parts can be shipped either:
• Still in sheets, or
• Detached from the sheet
• For detached parts, common packaging options include:
• Bulk packing
• Tubes
• Boxed in foam layers
• Pick-and-place trays
• Tape and reel

Metals and Material Selection

• Fotofab etches a wide range of standard and exotic metals, including non-corrosive and biocompatible options.
• Stainless steel and copper are common and easy-to-source materials when a specific alloy is not required.
• Fotofab's engineering and sales team can help customers select suitable materials for their application.

For more detailed or application-specific questions, customers should contact Fotofab directly through the website or by phone.

Major Certifications

• AS9100D and ISO 9001:2015 certified
• Includes quality requirements for ISO 9001, DOD, NASA, and FAA
• ITAR registered manufacturer
• RoHS compliant production available upon request
• REACH compliance documentation available
• Joint Certification Program (JCP) certification
• CAGE Code: 707X1
• System for Award Management (SAM) certified U.S. Government vendor
• DUNS: 078871203

Conflict-Free Mineral Policy

• Fotofab assesses its supply chain to comply with Section 1502 of the 2010 Dodd-Frank Act.
• Requires suppliers to submit a completed EICC/GeSI Conflict Minerals Reporting Template.
• Supports the goal of ending violence, human rights violations, and environmental harm in the Conflict Region.
• May reconsider working with suppliers that do not comply with its conflict minerals policy.

Environmental Commitment

• Commended by government regulatory agencies for environmental compliance and cooperation.
• Actively works to make manufacturing processes cleaner, safer, and more respectful of natural resources.
• Positions itself to meet growing customer emphasis on environmental responsibility.

Supplier Quality Requirements

• Fotofab maintains a Supplier Quality Manual that outlines expectations for suppliers.
• Customers and suppliers can request or review the Supplier Quality Manual via the main website.

Industry Focus for Certified Work

Fotofab's certifications and quality systems support customers in:

• Aerospace
• Military and defense
• Medical (including implantable parts)
• Telecommunications
• Electronics
• Energy and renewable energy
• Other high-reliability industrial applications

Ask anyway — the agent will say plainly that it is not published rather than guess.