Encoder Discs Overview

Xinhaisen produces high-precision, custom encoder discs for optical and magnetic rotary encoders using advanced photochemical etching. Our process manufactures discs with exceptional dimensional accuracy, clean burr-free features, and consistent performance, critical for reliable motion feedback in demanding industrial, automotive, and aerospace applications.

Manufacturing Process

Our encoder discs are crafted through a controlled, stress-free photochemical etching process:

• Design & Tooling: Your CAD design is used to create a digital phototool.

• Material Preparation: A selected metal sheet (stainless steel, copper alloy, etc.) is cleaned and coated with a photoresist.

• Precision Patterning: The phototool pattern is exposed onto the coated metal using UV light.

• Chemical Etching: The unexposed areas are etched away, forming the precise radial lines, slots, or absolute code tracks.

• Finishing & QC: The resist is stripped, and discs undergo cleaning, optional blackening, and 100% dimensional inspection.

Encoder Discs Features

• Extreme Precision: Achieve fine line widths down to 15µm and tight angular tolerances.

• Stress & Burr-Free: The etching process creates clean features without mechanical stress, heat distortion, or burrs.

• Excellent Consistency: Photo tooling ensures every disc and every batch is identical.

• Complex Designs: Easily produce intricate multi-track patterns, unique sector openings, or alignment marks.

• Rapid Prototyping: No hard tooling means fast, cost-effective design iterations and short lead times.

Encoder Discs Specifications

Encoder Discs Applications

• Optical Encoders: Incremental and absolute rotary encoders for servo motors, robotics, and CNC machinery.

• Magnetic Encoders: Disks with precise pole patterns for magnetic rotary position sensors.

• High-Speed Systems: Low-inertia discs for high-RPM motors and turbines.

• Precision Instrumentation: Components in medical devices, gauging systems, and scientific equipment.

Our Advantages

• Micro-Feature Specialists: Our core expertise in etching ultra-fine features (0.03mm holes, 0.015mm lines) guarantees superior encoder disc accuracy.

• Unmatched Flexibility: We efficiently handle both low-volume prototyping and high-volume production runs with rapid turnaround.

• Material Versatility: We process a wide range of alloys to meet specific mechanical, magnetic, or thermal requirements.

• Vertical Integration: Direct control over material sourcing and production ensures quality, cost-effectiveness, and reliable supply.

• Proven Industry Leader: Recognized by global clients for high precision, speed, and the ability to manufacture a vast array of complex parts.

FAQ

• Q: What are the key benefits of photochemical etching for encoder discs compared to stamping or laser cutting?
  A: Etching is stress-free (no magnetic property distortion), burr-free (prevents signal noise), and allows for more complex, higher-tolerance patterns without expensive hard tooling or thermal damage.
• Q: What information do you need to provide a quote?
  A: Please provide your CAD drawing (DXF/DWG/Gerber), material specification, thickness, annual volume estimate, and any critical tolerance callouts.
• Q: Can you achieve the required optical contrast for clear signal generation?
  A: Yes. We offer several solutions, including precision black oxide coating and the use of contrasting metal laminates (e.g., nickel on stainless steel), to ensure high signal-to-noise ratio.
• Q: What is your standard lead time for prototype quantities?
  A: Prototype lead times are typically 1-2 weeks after approval of the digital phototool, depending on material availability.
• Q: Do you offer any value-added services?
  A: Yes. We provide precision etching of alignment holes, optional cleaning/packaging per specification, and can laminate discs to polymer or metal hubs for assembly-ready parts.

Welcome to contact us at any time!