PEI produces high-performance aluminum components using advanced photochemical etching techniques. Our process enables lightweight, thin-gauge aluminum parts with intricate detail, tight tolerances, and minimal distortion – ideal for aerospace, electronics, automotive, medical, and industrial applications.
Aluminum is one of the most versatile and widely specified engineering materials in modern manufacturing. Its combination of low density, corrosion resistance, and electrical and thermal conductivity makes it essential across aerospace, electronics, automotive, and industrial systems.
However, manufacturing thin aluminum components presents challenges. Due to its relatively soft structure, aluminum sheet can deform, stretch, or warp when subjected to stamping or other traditional machining methods. Heat-based cutting can also alter the metal surface or introduce distortion in thin gauges.
The photochemical machining process offers a stress-free, heat-free alternative. Through controlled acid etching, PEI produces intricate aluminum components without introducing mechanical force or thermal damage. As trusted leaders in precision aluminum etching, PEI delivers consistent quality and dimensional accuracy for demanding applications.
Aluminum’s popularity in engineering design stems from its performance characteristics and adaptability across industries. Its unique combination of mechanical and electrical properties makes it a go-to material for lightweight yet durable metal components.
Key benefits include:
These characteristics make aluminum a highly adaptable solution across performance-driven industries.
We specialize in high-performance aluminum etching, from prototypes to full-scale production runs. Please see our Design Guide or Contact Us for more information about our additional manufacturing capabilities.
Density: 2.70 g/cm³
Melting Point: ~660°C (1220°F)
Thermal Conductivity: 150–235 W/m·K
Electrical Conductivity: ~35–61% IACS (alloy dependent)
Tensile Strength: 13,000–45,000 psi (alloy dependent)
Corrosion Resistance: Good to excellent in many environments
Common Grades: 1100, 3003, 5052, 6061
Our proprietary Eco-Chem™ photochemical etching process is engineered for precision, safety, and sustainability.
Minimizes Burr Formation:
Unlike mechanical or laser cutting, our process limits stress or heat distortion.
Eco-Friendly Chemistry:
We use proprietary, RoHS-compliant etchants (including hydrofluoric acid) designed to minimize environmental impact.
Metal Integrity Preserved:
Our proven process means no heat-affected zones or micro-cracks, maintaining the full strength of aluminum.
Rapid Turnaround:
We offer short lead times for prototypes and scalable production capacity.
Design Optimization:
Our engineers collaborate closely with you to optimize designs for manufacturability and cost efficiency.
Extensive Safety Precautions:
Our facilities adhere to rigorous handling protocols and employ advanced containment systems to ensure maximum safety during chemical etching operations.
Aluminum etched components serve a broad range of high-performance sectors, particularly in aerospace and defense applications where weight reduction and reliability are critical.
In aerospace systems, aluminum provides lightweight structural solutions for brackets, interior panels, and shielding components. PEI supports aerospace manufacturers with precision aluminum parts that meet tight tolerances and performance requirements.
See how we’re supporting the Aerospace and Defense industries.
Aluminum is widely used in electronics for EMI/RFI shields, heat management components, and enclosure structures. Its thermal and electrical conductivity support system stability while reducing overall device weight.
Learn more about our work in the Electronics industry.
In automotive and electric vehicle platforms, aluminum reduces weight while maintaining durability. Applications include battery components, structural supports, and shielding covers.
See how we serve the Automotive industry.
Medical and industrial equipment manufacturers rely on aluminum for device housings, instrument panels, and lightweight precision components.
Explore how our etching capabilities support the high standards required in Medical applications.
PEI delivers precision aluminum components through U.S.-based manufacturing backed by decades of expertise.
We provide:
Our team works closely with customers to ensure design intent is maintained throughout the photochemical machining process, delivering aluminum precision parts that meet exact application requirements.
PEI manufactures a wide range of aluminum precision parts for engineering applications, including:
These components often require complex geometries that would be difficult or costly to achieve through conventional processes.
We work with our partners to introduce new ideas and enhanced manufacturing solutions. Our engineers leverage the power of technology and decades of experience to ensure each design and plan will deliver the expected results, whether for the latest in renewable energy or a new life-saving medical technology.
PEI’s commitment to delivering thin metal parts and components utilizing precision photochemical etching dates back decades. We are the world’s leading etcher of titanium and can handle aluminum, beryllium copper, molybdenum, and many other metals. PCE is an ideal manufacturing process for rapid prototyping and high-production runs.
Our precision operators turn thin metal parts into reliable components with meticulous machine and manual forming techniques. PEI’s forming expertise starts at the first step, enabling us to develop highly accurate parts that our team forms to exact standards and specifications.
Protecting precision metal parts from corrosion, wear, and environmental hazards is job number one when applying coatings, finishes, plating, or paint. Finishing applications also offer antibiotic and aesthetic benefits to the parts we produce via photochemical etching.
PEI delivers durable and reliable assembled components found in power-generating, life-saving, and high-technology applications worldwide. Our expert team of engineers and operators will ensure our partners receive ready-to-implement solutions that will last.
The PEI Quality Assurance team analyzes every thin metal part and component to ensure its precision, accuracy, and durability. Our team uses a combination of technological and manual inspection techniques to check for imperfections before any part or component leaves our facility.
Industries and technologies evolve when people work together to push boundaries and uncover new solutions. For over 50 years, we’ve stood shoulder to shoulder as leading companies across every market sector push forward with revolutionary changes that change the world. We are ready to share and leverage knowledge and expertise to collaborate with our customers for mutual success.
Aluminum’s lightweight strength, corrosion resistance, and conductivity make it one of the most widely specified engineering materials across industries. When combined with PEI’s advanced chemical etching process, aluminum becomes an ideal solution for intricate, thin-gauge components requiring tight tolerances and minimal distortion.
If your application demands precision aluminum components with complex geometries and repeatable performance, PEI is ready to support your next project.
PEI’s long history of meeting and exceeding industry standards and customer expectations began in 1968. For over 50 years, we’ve kept quality assurance at the forefront of our work by training our manufacturing teams, maintaining our equipment, and establishing rigorous internal controls. PEI holds several certifications, including ISO9001:2015, AS9100:2016, and ITAR. We adhere to MIL-STD-45662, MIL-STD-105, and ANSI/ASQC Z1.4 quality standards.
