Etching aluminum front panels?

[Martin Czech]

> Does anyone have experience in etching aluminum ? This should preferably
> be done at home (Minimum toxic fumes, plastic trays, kitchen sink, etc.
> as in PCB making).
> 
> I've already done some test with FeCl, but due to oxidation it is almost
> impossible (well, not entirely, you just have to scratch the aluminum
> with a razor !). 
> NaOH is out of the qustion, since this is what I use to develop the
> Photoresist that transfers the markings.
> 
> I have very little knowledge in chemistry (which you might have guessed
> !), so any clues as how to proceed is welcome.
> 
Very good question indeed.
It must be possible with the right chemicals (acid, HCl ? or
NHO3 ? or a mixture of both ? dangerous and toxic !)
but there is another problem i stumbled about :
You have to do the photoresist coating of the aluminum
also at home.
How can we prevent dust particles from getting in the
photo coating ? Those particles tend to "suck up" the
photoresist thus causing ugly holes.
This happended to my self coated PCBs and the traces
had "spots".

I guess, a dust free cleanroom is required , or what ?

m.c.