Tech Etch has six decades of experience and expertise specializing in manufacturing precision-engineered thin-metal components, flexible printed circuits, and EMI/RFI shielding, across three locations in the United States (Plymouth, Massachusetts; Fall River, Massachusetts; and Litchfield, Minnesota). The company partners with leading global customers in the aerospace, alternative energy, military, medical, telecommunication, and electronics industries that have highly complex, precise designs, and demanding regulatory requirements.
Tech Etch has designed and developed a robotic spray coating process used to apply conductive carbon and graphite coatings to battery current collectors, fuel cells, thin-metal cathode grids used in implantable pacemaker batteries, and other energy storage devices that require low-resistance coatings. This coating provides a protective layer to slow down the erosion of the base metal and therefore helps to extend battery life.
Conductive coatings enhance battery performance with improved electrical contact between active materials and the current collector, resulting in longer battery life and reliable cycle life. They also provide oxidation and corrosion protection that enables aggressive electrolytes and provides extended shelf life by reducing leakage and self-discharge.
The spray system is designed to deliver both epoxy- and water-based coatings, and is built around a six-axis robotic arm equipped with an HVLP (high-volume, low-pressure) spray gun. It is programmed for highly efficient spray patterns that reduce material consumption and wasted overspray. The precise aim of this robotic system delivers coatings from all angles, and ensures even and complete coverage of components with very-tight coating thickness tolerances. The design also enables the company to mask areas without the use of adhesive. As such, custom fixturing and recycled paper materials can be used in place of wasteful plastics and/or rubber masking.
Tech Etch places a significant emphasis on waste reduction and sustainability as part of its overall operational strategy. The company has successfully transformed its waste management practices, achieving a point where none of its general waste is sent to landfills. This shift has enabled Tech Etch to prevent the disposal of approximately 200 tons of waste and save nearly 8,500 gallons of oil. Additionally, the company has innovatively utilized this waste to generate 110 MWh of renewable energy, equivalent to powering 10 suburban homes for a year.
Regarding infrastructure improvements to enhance energy efficiency and reduce the carbon footprint, the company has made substantial strides. It has adopted energy-efficient LED lighting, which has significantly reduced utility bills. Additionally, the company upgraded its roofing to a white membrane, which has helped lower temperatures inside the facility by up to 5 °F. This change, combined with enhanced insulation, has improved cooling efficiency and reduced heat loss. Furthermore, Tech Etch has optimized its heating and cooling systems by installing six new rooftop units and replacing three traditional boilers with two high-efficiency boilers. These infrastructure improvements are expected to save approximately 2,822 tons of carbon emissions, marking a substantial reduction in Tech Etch's carbon footprint.
Coatings such as the ones Tech Etch applies improve and prolong critical battery functions, and therefore reduce overall manufacturing waste as well as repetitive patient care. The Tech Etch spray system was engineered to provide high productivity at a high transfer efficiency, while also utilizing recycled masking materials. These attributes are certainly in line with the company’s desire to provide cleaner and more environmentally friendly solutions.
