How Much Material Does Electropolishing Remove?

Customers often ask us, how much material does electropolishing remove? Electropolishing, when done properly is a highly controllable process, which removes as little as .0001” per surface or .0002” total material. Material removal can be increased by adding more time and/or direct current to the process. Electropolishing will typically remove between .0002” to .0003” per surface depending on a part’s size and square footage.

There are many variables involved in the Electropolishing process such as time, amperage, bath temperature, bath chemistry, and specific gravity. New England Electropolishing has tightly controlled processes for thousands of parts that yield consistent repeatable results on each order.

Removal rates are generally very consistent assuming parts have the same starting thickness. Edges and radius generally have slightly more material removal as they are higher current areas. This is often a plus as burrs and high points will be brought down and removed. Additionally, the surface roughness of parts (Ra, RMS) will be reduced as more material is removed. On average, the surface roughness of parts can be reduced between 25-35% assuming a moderate amount of material removal.

Many of the parts we electropolish for the medical industry have strict tolerances. These are often critical components to a device where form, fit and function are essential. In these instances, NEE will measure parts before and during processing to ensure product consistency. Records are kept with each job order. Additionally, we can share removal data with our customers to maintain transparency and confirm results.

NEE often develops electropolishing processes for customers through product sampling. We often will provide customers with multiple groups of samples with different removal rates. Once we receive positive feedback, the electropolishing process will be locked in our ERP system for future orders.

Please consider New England Electropolishing for your next application. Our organization looks forward to developing an electropolishing process with your team!