Wire Electrical Discharge Machining (Wire EDM) is a specialized manufacturing process used for cutting intricate and delicate shapes in various conductive materials. This process utilizes a thin, electrically charged wire as a cutting tool, which slices through the material by means of a controlled electrical discharge (spark erosion). The wire, typically made of brass or stratified copper, acts as an electrode and is continuously fed from a spool through the workpiece, submerged in a tank of dielectric fluid, usually deionized water.

The key feature of Wire EDM is its ability to cut complex shapes with high precision and fine detail, without exerting mechanical force on the workpiece. This makes it ideal for producing intricate components and delicate parts that would be difficult or impossible to machine using traditional mechanical cutting methods. It’s especially useful for hard materials like hardened steel, titanium, and superalloys, or for parts requiring extreme dimensional accuracy and smooth surface finishes.

During the Wire EDM process, the workpiece and the wire do not make physical contact; instead, the material removal is achieved through a series of rapid, controlled electrical discharges (sparks) that occur in the small gap between the wire and the workpiece. These sparks generate intense heat that melts and vaporizes the material in a very localized area. The dielectric fluid helps to cool the process area, flush away the removed material, and insulate the wire and workpiece to control the spark discharge.

Wire EDM is widely used in industries such as aerospace, automotive, and tool and die making for creating complex parts, precision components, and intricate patterns. The process is known for its accuracy, versatility, and ability to produce fine details and smooth surface finishes.

We have a Charmilles Robofil Wire EDM Machine which is considered the industry standard. We also have a hole popper EDM to machine holes to either prepare a workpiece for Wire EDM or simply machine out a hole in a hardened part.