Laser-Cut vs Etched Shadow Masks | Resolution, Accuracy & Cost Guide

Laser-Cut vs. Etched Shadow Masks: Performance, Resolution, and Cost Comparison

Shadow masks are essential tools in thin-film deposition, microfabrication, device prototyping, and sensor research.
Two of the most common fabrication methods are:

  • Laser cutting (most common in R&D)
  • Chemical etching (photochemical machining, PCM)

Although both methods produce stainless steel masks, their resolution, tolerances, edge quality, and cost differ significantly.
This guide compares the two processes to help researchers and engineers choose the appropriate fabrication method.

Which Method Should You Choose?

⭐ Laser-cut masks → Best for precision, speed, and small batches

(Resolution: 30–40 µm, fast turnaround)

⭐ Etched masks → Best for thicker materials and large-volume production

(Resolution: 50–100 µm, smoother edges but lower precision)

If your focus is accuracy & small features, laser cutting is the superior choice.

Resolution Comparison

Method Typical Minimum Feature Size Edge Quality Notes
Laser Cutting 30–40 µm Slight taper, micro-burrs possible Best resolution for steel
Chemical Etching 50–100 µm Very smooth edges Undercut limits precision

Why laser is sharper:

Laser cutting’s beam spot allows micro-scale removal, while chemical etching causes undercutting, making features larger than intended.

Tolerance & Dimensional Accuracy

Parameter Laser Cutting Chemical Etching
Tolerance ±5–10 µm ±25–50 µm
Positional accuracy Excellent Moderate
Openings consistency High Medium

Chemical etching is strongly affected by material thickness, chemical concentration, and etch time → larger variation.

Thickness Capability

Laser Cutting

  • Works well from 0.03–0.5 mm stainless
  • Can cut even thicker materials (up to several mm)
  • Suitable for rigid masks & structural stability

Chemical Etching

  • Optimized for 0.05–0.3 mm
  • Thick materials produce severe undercutting
  • Not suitable for extremely fine micro-patterns

Heat Effects

Laser Cutting

Heat from the laser creates:

  • Heat-affected zone (HAZ)
  • Edge taper (slanted cut)
  • Minor burrs

But modern laser systems minimize these effects.

Chemical Etching

No heat distortion.
Edges are chemically dissolved → smooth but less accurate.

Cost Comparison

Method Cost per Mask Best Use Case
Laser Cutting Low–Medium Prototyping, research masks, micro features
Chemical Etching Medium–High (for small quantity) Large runs with repeated patterns

For low-volume research work → Laser cutting is almost always cheaper and more accurate.

When to Choose Each Method

Choose Laser Cutting if you need:

  • Features 30–40 µm
  • Tight tolerances
  • Fast delivery
  • Stainless steel stability in vacuum
  • Custom one-off designs or rapid prototyping
  • Choose Chemical Etching if you need:
  • Smooth edges
  • Larger features (>80 µm)
  • High-volume manufacturing
  • Medium-thickness steel (0.1–0.3 mm)

Frequently Asked Questions

Q1. Which method produces smaller features?

Laser cutting → 30–40 µm
Etching → 50–100 µm

Q2. Which method is better for thin-film deposition masks?

Laser cutting due to higher precision and better dimensional control.

Q3. Are etched masks smoother?

Yes — chemical etching produces smoother edges but poorer accuracy.

Q4. Can etched masks achieve 30 µm features?

No. Undercutting during etching limits resolution.

Q5. Which method is cheaper for research labs?

Laser cutting (especially for small batches or unique designs).

 

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