Encoder disks are the core components of high-precision rotary sensors, used to convert rotary motion into digital signals. These disks are typically made of circular metal or transparent substrates, patterned with precisely arranged lines or holes. These markings allow light to pass through or reflect back, enabling optical sensors to detect the rotation angle, direction, and speed.
The resolution of an encoder disk is determined by the number of lines on the disk—such as 1024 or 2048 lines—directly affecting the accuracy of angular displacement detection.
Encoder disks are widely used in:
Industrial automation systems and servo motors
Electric vehicle drive systems
Medical micro motors
Robotic arms and feedback encoders
They are critical components in achieving closed-loop control and high-accuracy motion feedback systems.
Wet chemical etching is an ideal process for manufacturing encoder disks with line widths above 50μm, which is common in mid-to-high resolution applications. Compared to laser or dry etching, wet etching provides several benefits:
Lower cost, especially for volume production
Stress-free fabrication, avoiding warping or damage
Material flexibility, compatible with metals like stainless steel and copper alloys
This makes wet etching a cost-effective and scalable solution for producing reliable encoder disks in industrial and mechatronic applications.
