PEI produces high-performance hafnium components using advanced photochemical metal etching techniques. Our process enables thin-gauge hafnium parts with intricate patterns, tight tolerances, and stable dimensional integrity, ideal for nuclear, aerospace, electronics, and high-temperature industrial applications.
Hafnium is a rare, high-performance refractory metal known for its ability to perform in extreme environments. It’s widely used in nuclear reactors for control rods and shielding, as well as in aerospace systems and high-temperature industrial applications where reliability is critical.
However, manufacturing hafnium components presents significant challenges. Thin hafnium sheets are difficult to machine or stamp due to their hardness, brittleness, and sensitivity to heat, which can lead to warping or cracking. These limitations make traditional fabrication methods costly and inefficient.
The etching process offers a precise, stress-free alternative. Through controlled chemical etching, PEI produces complex hafnium components without introducing mechanical force or thermal distortion. This innovative approach enables smooth etching of intricate designs while preserving the integrity of the base material.
Hafnium is a preferred material for applications where performance under extreme conditions is essential. Its unique physical and chemical properties make it indispensable in highly specialized industries, from aerospace to nuclear.
Key benefits include:
(~2,233 °C / 4,051 °F) – Suitable for sustained exposure to extreme heat.
Maintains stability in harsh, high-temperature environments.
Critical for components operating in nuclear and aerospace systems.
Essential for control rod and shielding applications in nuclear reactors.
Allows engineers to tailor performance characteristics for specific applications.
These properties make hafnium one of the most reliable materials for applications where failure is not an option.
Photochemical metal etching is an ideal solution for processing hafnium, especially in thin-gauge applications where traditional methods often pose risks.
Advantages include:
No mechanical stress – Reduces the risk of cracking in brittle hafnium.
No heat-affected zone – Preserves the material’s microstructure and performance characteristics.
Tight dimensional control – Enables precision components with consistent etch depth.
Supports complex geometries – Intricate features and fine details are achievable without tooling limitations.
Low tooling cost – Ideal for rapid iteration and design optimization.
Efficient for production – Scalable for medium-to-high volume manufacturing.
PEI’s controlled use of etchants, including hydrofluoric acid, allows for consistent, smooth etching across Hafnium surfaces while maintaining strict safety and process controls. The result is high-precision components that require minimal secondary finishing or surface treatment.
We specialize in high-performance Hafnium etching, from prototypes to full-scale production runs. Please see our Design Guide or Contact Us for more information about our additional manufacturing capabilities.
*Properties may vary based on material form and processing conditions.
Max 24” x 30”
Minimum 0.0005” — Max 0.200”
Min 0.005” or 110% of material thickness
Minimum 120% of material thickness
Material thickness
Approx. 75% material thickness
DIA + material thickness
± 10% material thickness, no less than ±0.001"
PEI manufactures a wide range of high-performance hafnium components using a tightly controlled etching process designed for accuracy and repeatability. Working with reactive materials like hafnium requires specialized expertise, particularly when processing thin-gauge material and maintaining consistency across complex geometries.
Our process utilizes carefully managed chemistries, including hydrofluoric acid, to achieve uniform material removal across delicate hafnium surfaces. This enables the production of intricate parts while preserving dimensional stability and minimizing the risks typically associated with machining brittle, high-value metals.
Common hafnium components we produce include:
Each component is engineered to meet strict performance requirements, ensuring reliability in extreme environments where material integrity and precision are critical.
Our proprietary Eco-Chem™ photochemical etching process is engineered for precision, safety, and sustainability.
Unlike mechanical or laser cutting, our process does not introduce stress or heat distortion.
We use proprietary, RoHS-compliant etchants (including hydrofluoric acid) designed to minimize environmental impact.
Our proven process means no heat-affected zones or micro-cracks, maintaining the full strength of hafnium.
We offer short lead times for prototypes and scalable production capacity.
Our engineers collaborate closely with you to optimize designs for manufacturability and cost efficiency.
Our facilities adhere to rigorous handling protocols and employ advanced containment systems to ensure maximum safety during chemical etching operations.
Hafnium components are critical in industries where performance under extreme heat, radiation, and environmental stress is required.
Hafnium is widely used in nuclear systems due to its neutron absorption properties. Applications include control rod components, neutron-absorbing shields, and high-temperature reactor parts that must maintain stability over extended operational cycles.
In aerospace applications, hafnium supports high-temperature environments, including thermal shielding, precision brackets, and structural components exposed to extreme conditions.
Hafnium is also used in advanced electronics and industrial systems, including heat-resistant foils and precision components that require long-term stability and corrosion resistance in demanding environments.
PEI combines advanced manufacturing capabilities with deep material expertise to support hafnium-based designs from prototype through production.
We provide:
Our team works closely with customers to ensure each component meets exact performance and dimensional requirements, delivering consistent quality across every project.
Following the etching process, PEI offers a range of surface treatment options to further enhance part performance, depending on application requirements. These treatments can improve corrosion resistance, surface condition, and compatibility with downstream assembly or operational environments.
Our team works closely with customers to ensure hafnium surfaces are prepared to meet exact specifications, delivering components that perform consistently in nuclear, aerospace, and high-temperature industrial applications.
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 team to 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.
Hafnium’s exceptional corrosion resistance, high melting point, and neutron-absorbing properties make it essential in nuclear, aerospace, and high-temperature applications. When combined with PEI’s precision photochemical etching capabilities, hafnium becomes an ideal material for producing complex, high-performance components with tight tolerances.
If your application requires precision hafnium components engineered for extreme environments, PEI is ready to support your next project.
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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.
