Custom Etched Optical Encoder Disc & Rotary Encoder Wheel for Motion Sensing

Product Overview

Xinhaisen specializes in the high-volume production of precision metal encoder discs (also known as code wheels or optical encoders). Using advanced photochemical etching, we produce intricate, burr-free patterns with tight tolerances. These discs are critical for converting mechanical motion into electrical signals in high-precision systems.

What is Etching?

Etching (photochemical machining) is a subtractive manufacturing process. A metal sheet is coated with photosensitive resist, exposed to a precise digital pattern, developed, and then chemically dissolved to create complex features. Unlike stamping or laser cutting, etching creates no burrs, no heat-affected zones, and no mechanical stress, making it ideal for thin, delicate encoder discs.

Product Features

• High Precision: Achieves positional accuracy of up to ±0.01mm (customizable).

• Fine Lines & Gaps: Minimum line width / space down to 0.02mm (20µm).

• Burr-Free & Stress-Free: Smooth edges ensure clean optical readings; no deformation.

• Material Versatility: Available in SUS301, SUS304, beryllium copper, nickel-silver, and other alloys.

• Custom Patterns: Supports incremental, absolute, or custom coded patterns.

• Thickness Range: 0.05mm to 0.4mm (ultra-thin for low inertia).

Product Specifications

Applications

Encoder discs from Xinhaisen are used in industries requiring precise motion control:

• Medical Devices: Surgical robots, motor control systems.

• Aerospace & Automotive: Steering angle sensors, throttle position sensors.

• Industrial Automation: Servo motors, stepper motors, robotic arms.

• Office & Consumer: Printers, scanners, high-end audio volume controls.

• Optical & Measurement: Optical encoders, tachometers.

Why Choose Xinhaisen?

• Rapid Prototyping: No hard tooling required; low NRE cost for custom designs.

• Scalability: From 10 pcs to 10 million pcs with consistent quality.

• Superior Quality: All discs pass strict flatness and optical inspection.

• Cost-Effective for Complex Parts: High-complexity patterns cost no more than simple ones.

• Fast Turnaround: Short lead times for urgent OEM/ODM orders.

FAQ

• Q1: What is the thinnest encoder disc you can make?
  A: We can etch encoder discs as thin as 0.05mm for ultra-low inertia applications.
• Q2: Can you produce a disc with a custom code pattern (non-standard slots)?
  A: Yes. We work from any 2D CAD or Gerber file. Custom patterns are our specialty with no extra tooling cost for prototypes.
• Q3: How does etching compare to laser cutting for encoder discs?
  A: Etching is superior for thin metals because it produces no heat burrs, no recast layer, and higher throughput for batch production. Laser may cause micro-burrs that affect optical performance.
• Q4: What is your typical lead time for a custom encoder disc?
  A: Prototypes: 5–7 working days. Mass production: 7–15 working days after approval.
• Q5: Do you offer surface finishing or post-processing?
  A: Yes. We provide deburring, cleaning, passivation, and flattening as needed.
• Q6: What quality standards do you follow?
  A: We follow ISO 9001:2015 quality management with 100% optical inspection for critical dimensions.

Welcome to contact us at any time!

For over 13 years Xinhaisen has pioneered developments in photochemical etching, achieving standards admired by the industry and appreciated by a global customer base from a wide range of high-tech engineering markets.

Since found in 2012, in affiliating with our customers we have pioneered many new production techniques and methodologies in order to better serve their needs. It is these techniques that have advanced our capabilities further, enabling us to take what was once considered art and turn it into a science.

Now, we became China's leading photochemical etching specialist, with also the capacity of offering stamping and laser-cutting service. Our products include etching bipolar plates for fuel cell, speaker grills,  micro meshes&filters, tea&coffee infusers, shims&gaskets, Optical encoderdisk&strip, EMI/RFI shielding, Leadframes, connectors&contacts, printingstencils&foils and metal crafts.

Quality and service is our mission, Xinhaisen is committed to pursuing the highest standards of environmental performance. Responsibility for sustainability resides with all employees. The company has achieved ISO 14001 and IS0 9001 and IATF 16949 and is committed to maintaining that standard. With a fast response, high quality, best service and fair price, we have gained high reputation from our customers all over the world.