Diffusion bonding creates strong and lasting connections between materials by heating and pressuring them together at the atomic level, without melting them. Complex 3D components can be produced by stacking and bonding photo etched plates, making it a versatile technique. In combination with photo etching, it allows for the creation of hollow structures, a feat that traditional molding methods cannot achieve. Diffusion bonding is widely favored in aerospace, medical, electronics, and power generation industries for its exceptional strength, minimal distortion, material versatility, and precise control. These qualities ensure reliable and durable components bonds.

Advantages of Diffusion Bonding + Photo Etching

  • Exceptionally strong and durable bonds
    The combination of photo etching and diffusion bonding processes ensures exceptionally strong and durable bonds between materials, enhancing componentlongevity and reliability.
  • Capability to produce complex 3D components
    Enabling the creation of complex 3D components that would be challenging or impossible to achieve using traditional manufacturing methods, expanding design possibilities.
  • Time and cost efficient process with no need for costly special mold
    Accelerating your design cycle and reducing overall time to market, as they don't require costly special molds.
  • Versatility from prototyping to mass production
    Offering versatility that covers the entire spectrum of production, from small-scale prototyping to large-scale mass production, providing cost-effective solutions at every stage.

Features

  • Minimal Distortion
    Since diffusion bonding is a solid-state process, it occurs at relatively low temperatures compared to traditional welding techniques. This means there is minimal distortion or warping of the materials being bonded, making it suitable for precision components.
  • No Filler Material
    Diffusion bonding does not require the use of filler materials like welding does. This can simplify the process and reduce the need for additional materials, reducing costs and potential contamination issues.
  • High Precision
    The process allows for precise control over the bonding parameters, such as temperature, pressure, and time. This control enables manufacturers to produce high-quality, tightly controlled bonds.
  • No melting or Solidification
    Unlike welding, which involves melting and solidification, diffusion bonding doesn't involve phase changes. This eliminates the risk of solidification defects and the formation of brittle intermetallic compounds in the joint.
  • Hermetic Sealing
    Diffusion bonding can create hermetic seals, which are impermeable to gases and liquids. This is valuable in applications where a leak-proof or vacuum-tight seal is essential.
  • Enhanced Mechanical Properties
    Diffusion bonding can improve the mechanical properties of materials, such as hardness, toughness, and corrosion resistance, which is essential in industries like aerospace and engineering.
  • Environmentally Friendly
    As diffusion bonding doesn't involve the use of filler materials and typically operates at lower temperatures than traditional welding, it can be considered a more environmentally friendly joining process.

Materials (Basically Same Materials)

  • Stainless Steel + Stainless Steel
  • 42 Alloy + 42 Alloy
  • Invar + Invar
  • Titanium + Titanium
  • Copper + Copper
  • Copper + Stainless Steel

Material Thickness and Number of Layers

Since our photo etching and diffusion bonding products are fully customizable to fit your components, please don't hesitate to reach out to us with your ideas.

Bonding Process Image

Principle of Diffusion Bonding

The principle of diffusion bonding is based on the phenomenon of solid-state diffusion, where atoms or molecules move through a solid material without the material melting. Therefore, joining is theoretically processed by bringing two metals close together with temperature ,crucially below the melting points of the material, and pressure. At these temperatures, atoms from one material diffuse into the other, forming a metallurgical bond at the atomic level. This controlled diffusion leads to the creation of a durable and distortion-free joint between the materials, making diffusion bonding ideal for precision components.

Applications    

  • Heatsink / Cooling Plate
  • Vapor Chamber
  • Heat Exchanger part
  • Fuel Cell Separator
  • Printer head
  • Mesh Filter
  • Jig
  • Transport Carrier
  • Mask
  • Encoder Slit
  • Semiconductor manufacturing jig
High Aspect Filter
Industrial filters: Photo etching followed by stacking over 1000 sheets and then diffusion bonding. Hole size and design is fully customizable.
Transport tray for efficient manufacturing process.
Ideal for micro electronic components due to its precision and versatility.

UPT Advantages

  • Precision Tolerance Control through Photo Etching Expertise
    With our specialization in photo etching, we excel in achieving and maintaining tight tolerance control. Our expertise ensures that your components meet the most stringent precision requirements, even in high-precision applications.
  • Production Flexibility with Stringent Quality Control
    Serving a global smartphone manufacturer as our end user, we understand the importance of flexibility of production. Our capabilities allow us to seamlessly scale up production while maintaining stringent quality standards. This ensures that your components meet the rigorous demands of global supply chains without compromising on quality.
  • Comprehensive One-Stop Solution
    Beyond our core competencies in photo etching and diffusion bonding, we offer a complete one-stop solution for your production needs. Whether you require additional processes such as plating or machining, we take care of the coordination and management of all necessary technical suppliers. This simplifies your production workflow, streamlining the process and ensuring that your ideal production is achieved efficiently.

Talk to Us about Your Project

Since our high-precision diffusion bonding products are fully customizable to fit your production line, please don't hesitate to reach out to us with your ideas.