Abstract
The potential of a photofabrication process involving photolithography and electrochemical milling has been established for the production of accurate holes in a range of sheet materials (10–500 μm thick), including molybdenum, platinum, Pt-10Rh, sterling silver, carat gold and silver- and palladium-based alloys. Based on scanning electron microscopy, the new technique shows its unique capability of producing high quality components in materials which were hitherto considered to be difficult or impossible to fabricate. Furthermore, the technique does not involve the use of any highly toxic or aggressive chemicals; a non-passivating neutral solution of sodium chloride is used as the electrolyte. Details of the type, concentration and application of the electrolyte are discussed. The technique appears to be potentially attractive to the manufacturers of fine apertures and similar intricate shapes of industrial components and jewellery items.
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