Photochemical machining (PCM), also known as photoetching, photofabrication or
photochemical milling, is a non-traditional manufacturing method based on the
combination of photoresist imaging and chemical etching. PCM uses techniques
similar to those employed for the production of printed circuit boards and
silicon integrated circuits. The PCM industry plays a valuable worldwide role in
the production of metal precision parts and decorative items. Parts produced by
PCM are typically thin, flat, and complex. These parts have applications in
electronics, mechanical engineering, and the aerospace industry. The increasing
popularity of industrial applications, together with greater competition, means
that there is a need to understand the costs involved in PCM so that the right
technology can be selected for manufacturing. The paper identifies the costs
involved in Photochemical Machining and presents a cost model for PCM using a
bottom-up approach. The research used IDEF3 representation (work breakdown
structure, WBS) to identify the process used in PCM. Expert interview,
literature survey, and participant observation were used to identify cost
drivers at each stage of the manufacturing process. The WBS and the cost drivers
were used to develop the cost model, which is focused on stainless steel
machining. Spreadsheets were used to implement the model, while the workbook is
divided according to the main process steps and general costs. The worksheets
contained in this workbook are: General Costs, Produce Drawing, Process
Phototool, Select Metal, Prepare Metal, Coat the Metal, Process Photoresist,
Etch Metal, Strip Photoresist, and Check & Package. Each of these sections
is divided into the following types of costs: Materials, Direct Labour,
Environmental and Indirect Costs. The workbook contains relevant data acquired
from the PCM laboratory at Cranfield, PCM industry, and literature. The model is
validated through expert judgement obtained on case study results. The model
presented in this paper can be extended to include other PCM techniques to
machine other materials
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