In today’s competitive manufacturing environment, welding quality assurance is non-negotiable for OEMs. Since 2024, ATACO Steel Products Corporation has operated a state-of-the-art Cut & Etch Laboratory, a facility that redefines how we deliver documented weld quality for critical applications across industries.
What Is Cut & Etch (Macroetch) Testing?
Cut & etch testing, also known as macroetch or metallographic testing, is a destructive process where a welded sample is sectioned, polished, and chemically etched to reveal its internal structure. This method verifies fusion penetration, reinforcement consistency, and potential discontinuities before a part ever enters service.
Each macroetch test includes:
- Precision sectioning across the weld axis
- Multi-stage grinding and polishing for a mirror finish
- Controlled chemical etching to define zones between base metal, weld metal, and HAZ
- Digital inspection and documentation of weld geometry
Visual, fast, and non-destructive to the full production run, macroetch testing helps validate compliance with standards like AWS D1.1, ISO 3834, AWS 14.3, and customer-specific weld requirements.
Why Metallographic Testing Matters for OEMs
Higher Reliability for Demanding Applications
In industries like construction equipment, agricultural machinery, and material handling systems, a single weld defect can compromise a multi-ton assembly. Aerospace and automotive manufacturers have long used metallographic evaluation as a core element of quality assurance. ATACO makes that same level of insight available for structural parts, deep drawn shells, and custom metal fabrication.
Critical for PPAP Submissions
Today’s Tier-1 and Tier-2 suppliers often require macroetch documentation as part of the Production Part Approval Process (PPAP). Our in-house lab enables faster validation, ensuring that your custom metal stamping and sheet metal fabrication consistently meet performance expectations.
Shorter Development Cycles
Speed matters. With ATACO’s internal capabilities, you can transition from prototype to production with fewer delays. Weld integrity is verified early, giving you a competitive edge in fast-paced manufacturing cycles.
Inside the Lab: Purpose-Built for Manufacturing Excellence
To deliver repeatable weld testing with minimal lead time, ATACO invested in advanced tools purpose-built for custom metal fabrication:
Process Step | Stamped Deck (Deep-Drawn) |
Precision Sectioning | Buehler AbrasiMet® M abrasive saw |
Grinding & Polishing | Buehler EcoMet® 30 twin-station system |
Chemical Etching | Sentry Air Systems Winged Sentry fume hood |
Digital Microscopy | Dino-Lite EdgePLUS™ 8 MP microscope & 4K monitor |
Certified Inspection | ASNT Visual-Testing Level II personnel |
Built for Precision, Speed, and Repeatability
Our AbrasiMet M saw includes a 5.5 hp motor and accepts 10–12″ blades. It delivers clean sectioning with minimal distortion. The EcoMet 30 provides flexible platen compatibility and high throughput, as has been proven over 2,500 hours in a lab environment.
Key Benefits of ATACO’s Cut & Etch Capabilities
- Faster Turnarounds for PPAP and First Articles
Skip the delays of third-party labs. Our in-house Cut & Etch Lab generates fast, high-resolution cross-section weld images, accelerating your sheet metal fabrication approval process.
- Measurable Weld Penetration for Every Run
ATACO routinely tests welds from our robotic welding systems and multi-axis fixturing to ensure compliance with penetration depth, bead profile, and throat geometry. This approach is ideal for applications involving deep draw metal stamping, custom steel fabricators, and large tonnage stampings used in heavy-duty equipment.
- Integrated Manufacturing & Quality
Our Cut & Etch Lab integrates seamlessly with our other metal fabrication services, including 5-axis laser cutting, custom CNC machining, and steel stamping services. That means fewer handoffs, fewer errors, and a single accountable partner from start to finish.
- Lower Total Cost of Quality
Testing in-house cuts lab fees and helps us reinvest in technology upgrades and process control. The result? Better part consistency and improved pricing for your next sheet metal fabrication or welded assembly project.
What Engineers Look for in a Fabrication Partner
Engineers don’t just want a part – they want confidence. ATACO delivers:
- Verified weld quality, documented through every stage
- Proven expertise in sheet metal fabrication for construction equipment and off-highway vehicles
- A steel fabricator with on-site macroetch capabilities
- Seamless pairing of custom metal stamping with PPAP and quality control
- A fast, domestic option for metallographic testing and precision metal stamping parts
Trusted Compliance for Industry Standards
Our lab supports conformance verification for:
- AWS D1.1 – Structural welding code
- ISO 3834 – Global fusion welding quality standards
- AWS 14.3 – Welding criteria for construction/ag applications
- Customer-defined quality protocols
Certified Welds, Documented Results
Complex projects demand proof. That’s where ATACO stands out.
We combine decades of deep draw stamping expertise with robust robotic welding and advanced macroetch testing, right here in Cedarburg, Wisconsin. For custom metal parts manufacturing, metal stamping, or pressure vessel fabrication, our integrated model minimizes supply chain complexity and accelerates your timeline.
Let’s Get You Weld-Certified
Need to verify weld quality for a new product launch or production ramp-up? Let’s talk. Contact us today to discuss scheduling a live Cut & Etch Lab demo, including macroetch testing in your next RFQ, or learning how combining metal laser cutting, deep draw metal stamping, and welding inspection can streamline your next project. We’re ready to help you reduce risk, cut lead time, and ship with confidence.
