[NightHawkInLight] wants what may be the impossible – a dirt cheap replacement for a laser cutter or a water jet. He’s got this crazy idea about using electrolysis to etch sheet steel parts, but he just can’t get the process to work. Sounds like a job for the Hackaday community.
In theory, electrolytic cutting of metal is pretty simple to understand. Anyone who lives in the northeast of the USA knows all about how road salt can cut holes in steel given enough time – say, one winter into payments on that new car. Adding a few electrons to the mix can accelerate the process of removing metal, but doing so in a controlled manner seems to be the crux of [NightHawkInLight]’s problem.
In his research into the method, he found a 2010 video by [InterestingProducts] of etching reed valves for DIY pulse jet engines from spring steel that makes it look easy. [NightHawkInLight] deviated from the reed valve process by substituting baking soda for salt to avoid the production of chlorine gas and changed up the masking technique by using different coatings. We applaud the empirical approach and hope he achieves his goal, but we tend to agree with frequent-Hackaday-tipline-project notable [AvE]’s assessment in the YouTube comments – the steel is just too darn thick. Once the etching starts, a third dimension is created at 90° to the surface and is then available to electrolyze, causing the corrosion to extend under the masking.
What does the Hackaday hive mind think? Is there any way to fix this process for thicker steel stock? Narrower traces, perhaps? Somehow modulating the current in the tank? Perhaps using the Hackaday logo would have helped? Chime in down below in the comments, and maybe we can all throw out our laser cutters.