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Wire EDM Machining Service
Precision Wire EDM Machining Services
Industries have the best wire EDM cutting with tolerances as precise as ±0.0001”. From the aerospace industry to the medical field, every precise part that meets the highest standards is produced.
Technical Specifications
Precision Wire EDM Specifications
Industry-leading technology delivering the highest precision for your challenging applications.
Tolerance
±0.0001“
Possible on precision parts with multiple skim passes.
Surface Finish
8-16 Ra µin
Achieved with mirror-like finish on a multi-pass cut.
Max Part Size
40″ × 27″
Able to handle larger workpieces that are 15″ thick.
Taper Cutting
30°
Complex tapered profiles with draft angles.
Gallery of Custom Wire EDM Cutting Service Parts
Come see the pictures of custom-made Wire EDM cutting service parts made for you with high precision.
Materials
Materials We Machine
Wire EDM can cut through anything conductive regardless of how hard that material is—soft aluminum to hardened carbide.
Expertise Across 100+ Materials
We have been optimizing processes for over 10+ years which allows us to recognize and understand the nuances of various materials and configurations. For working with 62 HRC prehardened tool steel and thin titanium alloys as used in medical implants, we fine-tune the parameters to maximize the machining outcomes.
- Tool Steels (D2, A2, O1, H13)
- Titanium Alloys (Ti-6Al-4V)
- Inconel & Hastelloy
- Tungsten Carbide
- Stainless Steel (304, 316, 17-4PH)
- Aluminum (6061, 7075)
- Copper & Brass
- Cobalt Chrome (Medical)
Tolerance by Material Type
| Material | Standard | Achievable |
|---|---|---|
| Aluminum 6061 | ±0.002″ | ±0.0005″ |
| Tool Steel (Hardened) | ±0.003″ | ±0.0008″ |
| Titanium Ti-6Al-4V | ±0.004″ | ±0.001″ |
| Inconel 718 | ±0.005″ | ±0.001″ |
| Tungsten Carbide | ±0.003″ | ±0.0008″ |
| Stainless 316 | ±0.002″ | ±0.0005″ |
100+
Materials Processed
10+
Years Experience
62 HRC
Max Hardness
±0.0005″
Best Tolerance
Trusted Across Critical Industries
On medical devices that save lives and aerospace parts that are mission-critical. We deliver precision that matters.
Aerospace & Defense
Components made for ITAR compliant technologies for use in commercial and military aircraft, spacecraft, and defense systems.
Typical Parts
- Turbine blades & vanes
- Fuel system components
- Landing gear parts
- Structural components
AS9100D
ITAR
NADCAP
Medical Devices
Life-critical implants and surgical instruments made with FDA-compliant quality standards.
Typical Parts
- Orthopedic implants
- Surgical instruments
- Cardiovascular devices
- Bone screws & plates
ISO 13485
FDA 21 CFR
Tool & Die
Complex dies, tooling components, and other such parts are fabricated from hardened compounds using high-precision methods.
Typical Parts
- Stamping dies & punches
- Injection mold inserts
- Extrusion dies
- Precision fixtures
ISO 9001
IATF 16949
The Wire EDM Advantage
What differentiates our wire EDM service from competing firms.
Unparalleled Accuracy
We deliver tolerances of ±0.0001″ with positional accuracy of 0.00004″. Each of our machines is calibrated daily to ensure the best results.
No Force No Stress
Our non-contact cutting approach does not exert mechanical stress on any of your parts, which is optimal for thin walls, intricate structures and fragile materials.
Cut Any Degree of Hardness
No matter the hardness of the material, cutting speeds remain unaffected. We machine pre-hardened tool steels at 60+ HRC just as easily as softer ones, like aluminum.
Complex Geometries
Our wire EDM process can easily achieve sharp inner corners, intricate profiles, and other features that are challenging to make with conventional machining. Minimum corner radius of 0.001″.
Our Track Record Speaks
99.7%
On-Time Delivery
99.9%
Quality Rate
10K+
Parts Monthly
500+
Active Customers
State-of-the-Art Wire EDM Machines
We invest in the latest technology to deliver superior results
GF AgieCharmilles CUT P
Quantity
6 Machines
Travel (X×Y×Z)
21.6″ × 13.7″ × 15.7″
Max Taper
30° / 8″
Accuracy
±0.00004″
Surface Finish
Ra 0.1 µm
Mitsubishi MV Series
Quantity
4 Machines
Travel (X×Y×Z)
15.7″ × 27.5″ × 16″
Max Taper
30° / 12″
Accuracy
±0.00008″
Auto Threading
Yes
Inspection Equipment
CMM
Zeiss Contura
Accuracy 0.00004″
Optical Comparator
OGP SmartScope
High Precision Optics
Surface Roughness
Mitutoyo SJ-410
Ra Measurement
Environment
Climate Controlled
68°F ± 1°F
Customer Success Stories
Real-World Wire EDM Solutions
Learn what challenges we have overcome from different sectors like aerospace, medical, and industrial industries with the help of our wire EDM machining services.
Case Study #2024-A1
Precision Turbine Blade Root Forms for Jet Engine Manufacturer
Aerospace & Defense
Material
Inconel 718
Hardness
44 HRC
Tolerance
±0.0002″
Quantity
2,400 pcs
Surface Finish
16 Ra µin
Certification
AS9100D
The Challenge
Tier 1 aerospace suppliers had to supply highly complex fir-tree root forms for commercial jet engine turbine blades. These parts demanded extreme tolerances in the machining of Inconel 718 superalloy (44 HRC) hardened state. Traditional machining methods were leading to severe tool wear, inconsistent surface finishes, and drifting of parts dimensionally after 15-20 pieces. Given the AS9100D certification requirements and 2,400 blades in an order, a dependable method that kept within the tolerances of ±0.0002″ throughout the run was necessary.
Our Solution
- Used a 5-pass cutting sequence including a rough cut followed by 4 skim passes to attain 16 Ra µin surface finish with no additional operations.
- Applied 0.010 inch brass wire with an optimized flushing pressure calibrated for the particular low thermal conductivity of Inconel 718.
- Used custom fixturing so we could work on 8 parts in one setup which helped us lessen the handling time while achieving a repeatable positioning of 0.0001 inch.
- Used a 68 ±1°F temperature controlled room for the duration of the project to avoid thermal drift from the 16 hour cut time.
- Used in-process CMM verification every 50 parts while fully documenting FAI.
100%
Parts Within Spec
0
Rejects
35%
Cost Reduction
8 weeks
Delivery Time
We were doing conventional machining for a few months and had a lot of trouble. Therefore, we found a partner that really understands how to do aerospace tolerancing. They do wire EDM processes and were able to achieve every single one of the blade roots, which we thought was impossible with inconel. The detailed FAI packages made quality audits a breeze. Now they are our go to for every single one of the critical path components.
Case Study #2024-M1
Micro-Feature Surgical Instrument Components for Minimally Invasive Surgery
Medical Devices
Material
17-4 PH SS
Slot Width
0.008″
Aspect Ratio
31:1
Corner Radius
0.002″
Surface Finish
8 Ra µin
Certification
ISO 13485
The Challenge
A top medical device maker was making their next-generation laparoscopic grasper, featuring jaw geometry, including internal ratcheting mechanisms with internal serrations that are 0.008″ and 0.250″ deep (31:1 aspect ratio). The internal corners are 0.002″ for better gripping of the tissue. The internal corners are sharp and the parts are made of 17-4 PH stainless steel in the H900 condition. The parts need a perfect finish to avoid damages and also to comply with the biocompatible regulations of the FDA. The previous contractors discarded the work, saying that it was too complicated to produce.
Our Solution
- Using molybdenum wire 0.004″ in diameter to obtain the 0.002″ corner radius while also keeping wire tension stability in deep slots.
- We developed a “pulsed flushing” technique on a wire EDM that was able to maintain dielectric flow in the extreme aspect ratio slots without causing wire vibration.
- We compensated for taper with advanced programming. We were able to maintain straight walls with a tolerance of 0.0003″ for an entire 0.250″ depth cut.
- We achieved a polishing finish of 8µin Ra with no secondary operations by executing a series of 6 skim passes at progressively lower power.
- For every single operation performed, a record was kept to maintain complete lot traceability, and to comply with the requirements for FDA 21 CFR Part 820.
99.8%
First Pass Yield
0.002″
Corner Radius Achieved
Passed
FDA Audit
12 mo
Ongoing Contract
When three other shops told us that our design could not be manufactured, we were ready to compromise on the design functionality. Instead, we sought other experts who viewed the challenge as an opportunity. The micro-slots they produced have sharper features than what we originally specified, and our surgeons are happy with the grip performance. Since then, we have transferred all our crucial EDM work to their facility.
Case Study #2024-T1
High-Volume Progressive Die Components with Sub-Micron Accuracy
Tool & Die
Material
D2 Tool Steel
Hardness
60-62 HRC
Tolerance
±0.0001″
Components
127 pieces
Clearance
0.0008″
Timeline
3 weeks
The Challenge
An automotive stamping supplier needed to replace a 47 station progressive die that makes 15 million electrical connector terminals a year. The die was originally built 8 years ago, but there are no longer replacement punches and dies available from the original toolmaker. Crucial dimensions of the tool have to match the original to within 0.0001″ to ensure proper press timing and part quality are maintained. The die was built out of D2 tool steel, hardened to 60-62 HRC, and had complex forming profiles with clearances being as tight as 0.0008″ for a 0.008″ brass strip.
Our Solution
- All parts of the rebuild were precisely measured using our Zeiss Contura CMM to capture measurements to a resolution of 0.00002″.
- Using the CMM data, we programmed our wire EDM to cut the parts. We optimized cut sequences to reduce the amount of thermal distortion caused from the wire to the hardened D2 material.
- All 127 parts were programmed to cut on 6 machines. Quality inspections were done during the run on each machine when the parts reached 25%, 50%, and 75% of total completed.
- For parts cut on wire EDM, if the part thickness was more than 2 in, we used submerged cutting. This was done to reduce taper, and all parts retained thickness to a tolerance of 0.0001″.
- Upon completion, we sorted the parts, then ground each pair of punches and die sets. Each punch and die pair was given a unique serial number along with a certificate of dimensions and quality.
18 days
Total Delivery
$0
Die-In Adjustments
$340K
Downtime Avoided
15M+
Parts Since Rebuild
We were about to experience an 8-week shutdown waiting for a new die. In 18 days, they delivered a full 127-piece rebuild that fit our press without needing any adjustments—in our industry, that is virtually unheard of. The die has produced more than 15 million parts without a single quality problem. We have already contracted them for the next 3 die builds.
Case Study #2024-C1
Tungsten Carbide Extrusion Die with Complex Internal Profiles
Industrial Tooling
Material
Tungsten Carbide
Hardness
92 HRA
Void Openings
14 profiles
Draft Angle
3° taper
Die Thickness
4.5″
Tolerance
±0.0005″
The Challenge
A specialty aluminum extrusion firm specializing in custom extrusion profiles needed a complex multi void die. The die needed to have 14 individual void openings with bearing lands needing ±0.0005″ precision to accommodate 3-degree draft angles for material flow with a polished finish for the aluminum flow finish characteristics. The material tungsten carbide (91% WC, 9% Co, 92 HRA) posed extreme machining obstacles with potential diamond grinding quoted as prohibitively expensive at $48,000 and conventional sinker EDM not able to achieve the corner sharpness requirements needed.
Our Solution
- Used the tapering Mitsubishi MV Series 30° taper over 12 inches to design the 3° draft angles in a single setup.
- We picked 0.008″ Brass Wire for a carbide cut. It was optimized to keep a balance of speed cut and the requirement of the surface finish.
- The design of tapered-sided profiles with corners on the sinker EDM finished was impossible to conventional methods, which were programmed to continue on four axes to interpolate for a tapered profile.
- Employed a specialized low-energy finishing pass for critical contact surfaces of aluminum extrusion to remove recast layers.
- Before the profiles were packaged, the 14 void profiles were fully verified with a CMM and an optical comparator finalized.
65%
Cost Savings
5 days
vs. 6 Weeks Grinding
Perfect
First Article
250K lbs
Aluminum Extruded
We received one quotation for diamond grinding costing $48,000 with a 6-week lead time. Wire EDM delivered the same, albeit better, die with sharper corners for $17,000 in 5 days. That die has processed over 250k lbs. of aluminum with no visible wear. We already ordered 3 additional carbide dies for new product lines.
Advanced Wire EDM Calculators
Technical tools to optimize your Wire EDM design and manufacturing process
Wire Diameter & Kerf Width Calculator
Calculate the actual kerf (slot) width for your Wire EDM cut
inch
Kerf Calculation Results
Wire Diameter
—
Kerf Width
—
Spark Gap (per side)
—
Min Inside Corner
—
Enter parameters to calculate kerf width.
Wire Selection Guide
0.004″ for intricate details, min corner 0.002″
0.010″ most common, good speed/accuracy balance
0.012″ fastest cutting, thicker materials
Design for Wire EDM Checker
Verify your part design meets Wire EDM manufacturing requirements
inch
inch
inch
inch
:1
deg
Design Analysis
Analysis complete.
Cutting Time Estimator
Calculate estimated Wire EDM machining time for your part
inch
inch
Time Estimate
Cut Speed
—
Time Per Part
—
Total Machine Time
—
Estimated Lead Time
—
Estimates based on standard conditions.
Request Accurate Quote
Material Machinability Guide
Compare Wire EDM performance across different materials
Material Properties
Cut Speed Rating
—
Surface Finish
—
Typical Hardness
—
EDM Suitability
—
| Property | Value | Notes |
|---|
Select a material for detailed EDM machinability data.
Prepared to begin precision wire EDM?
Send your CAD file to us and get your detailed quote within one day. Our engineering team is ready to help you with your project.
Get Instant QuoteWire EDM Services FAQs
Electric discharge machining, abbreviated as EDM, is a process by which a machine uses electrical current to remove conductive metal from a workpiece. It achieves this by generating a spark from a discharge electrode or thin wire to the workpiece while a dielectric fluid, most commonly deionized water, is used. EDM differs from conventional machining because, while conventional machining involves a cutting tool that contacts the workpiece directly, EDM bypasses the need for mechanical cutting altogether. This process is most useful for machining brittle workpieces, hardened metal, or complicated geometries that are hard to machine using conventional methods, and includes wire EDM and sinker EDM options as well.
For high precision wire EDM machining one of the most critical factors is the electrode wire used. With a thin electrode wire, the EDM can achieve cuts on the workpiece with micron level accuracy. This process is controlled through either CNC or EDM systems and is able to achieve very tight tolerances and fine surface finishes on EDM wire parts. Because of this, manufacturers are able to create highly detailed workpieces which include intricate shapes, fine contours, and even precision arrays when multiple holes need to be machined in the workpiece.
Some benefits of electric discharge machining are the capabilities of produce intricate internal contours and forms which are costly or impossible to manufacture from a solid blank using a traditional cutting tool. No mechanical stresses are induced to the part, and it can be utilized on hard or brittle materials. It produces a better surface finish than other non-conventional machining processes, and the process has repeatable highly accurate results. Wire EDM is especially good in producing precision parts in high volume and tight tolerances, typically in the aerospace and automotive industries, as well as in die and mold machining.
Certainly, a major of EDM machine shops and metal working shops integrate CNC machining and wire cut EDM, and it is to maximize the benefits of both processes. A component can be rough machined through conventional machining or waterjet cutting, and then finished with wire edm to achieve the required tolerances, precision surface finish, and to add on intricate machining features to the part. Integrative manufacturing services usually consist of a mixture of prototypes, mass production, and part processing.
EDM wires act as electrodes and facilitate the generation of electric energy, which concentrates on the area around conductive materials, causing them to vaporize, but with no mechanical contact. This thin wire approach EDM performs is perfect for materials that need cutting and have fine details (thin sections, slots, intricate patterns) as it retains a decent surface finish and accuracy to the required dimensions.
EDM Processes utilize dielectric fluids, usually deionized water for wire EDM, to displace particles and provide a stable environment for the fluid. Pulse energy is controlled at the wire and the fluid is fed to allow the spark to decrease, this controls the thermal energy in the workpiece so that the surface finish is smooth on the side of the workpiece and the recast layer is thin. Quality machine and EDM settings are used to allow the part to have good surface finish and secondary operations.
Wire EDM services are best suited for aerospace and automotive applications. EDM wire is precision-machined and allows for the machining of hard and heat-sensitive materials, while being able to produce complex parts within tight tolerances. EDM wire machining aids in the development and manufacture of high-performance parts for the thin electrodes of microfeatures, hole edm for cooling channels, and complex geometries for these industries.
When you are selecting an EDM department, you should expect a full spectrum of machining capabilities to include wire electrical discharge machining for precise wire cutting, sinker edm for cavities, and complex shapes plus process planning for dielectric management, and finishing to achieve the required surface finish and tolerances. Such services would include requesting a quote for parts to be produced along with advice on material suitability (substrate metal and conductive materials), alternatives for either high mix low volume or prototype runs, and post integration with other manufacturing services and metal fabrication.
