Custom Wire EDM Machining Services Intricate Cuts in Hardened Materials
Wire Electrical Discharge Machining (Wire EDM) is a non-contact manufacturing process that uses electrical discharges (sparks) to erode material from a conductive workpiece. Wire EDM machining provides high precision cutting for hardened steel, tool steel and complex profiles. Unlike conventional CNC machining that relies on cutting tools, Wire EDM removes material through controlled thermal erosion, enabling precision cuts in hardened steels, carbides, titanium, and exotic alloys — materials that are difficult or impossible to machine with traditional methods. Wire EDM is ideal for molds, tooling components, thin wall structures and intricate parts that require tight tolerance machining.
Our EDM capability ensures burr-free cutting, excellent surface finish and accurate dimensional control.
Our Wire EDM Capability:
A thin, electrically charged brass or coated wire (typically 0.10mm to 0.30mm in diameter) travels between two guides, passing through the workpiece without touching it. The wire and workpiece are submerged in deionized water, which acts as a dielectric fluid. Thousands of controlled electrical discharges per second jump the gap between wire and workpiece, melting and vaporizing microscopic particles of material. The wire never makes physical contact, resulting in zero mechanical stress and a burr-free finish.
-- Hardness Independence: EDM cuts any conductive material regardless of hardness — tool steel at HRC 60+ machines as easily as annealed material
-- No Cutting Forces: Delicate or thin-wall parts won't deform during machining
--Sharp Internal Corners: Achieve true 90-degree corners with tiny radii (0.05mm or less)
--Burr-Free: Parts come off the machine ready for assembly or further processing
Send your STEP/IGES files. Our engineers review part geometry, material hardness, and tolerances — confirming Wire EDM is the optimal process.
Receive a transparent quote with lead time, wire selection, and finishing options. No surprises.
Submerged cutting in deionized water with real-time monitoring. Multi-pass strategy applied for surface finish requirements.
CMM verification of critical dimensions, burr-free parts, careful packaging, and global shipping with full tracking.
We stock a comprehensive range of metals and plastics to meet diverse application requirements—from lightweight aerospace components to corrosion-resistant medical devices.
Category | Common Grades | Typical Applications |
Hardened Tool Steel | A2, D2, O1, S7, M2 (HRC 55-65) | Stamping dies, punch holders, forming tools |
Stainless Steel | 304, 316L, 17-4, 420 (hardened) | Medical devices, surgical instruments, food-grade tooling |
Carbide (Tungsten) | Micro-grain carbide, C2, C5 | Wear parts, slitter blades, precision punches |
Titanium | Grade 2, Grade 5 (Ti-6Al-4V) | Aerospace components, medical implants |
Superalloys | Inconel 718, Hastelloy, Monel | Turbine components, chemical processing parts |
Copper & Brass | C110 Copper, C360 Brass | Electrodes, electrical contacts, EDM electrodes |
Need a material not listed? Contact us with your requirements. We can source and machine most conductive materials.
We offer a range of standard post-processing options to enhance appearance, durability, and performance. All finishing is coordinated in-house to ensure seamless project management.
Finish Type | Description | Best For |
As-EDMed | Standard finish with fine recast layer (typically 0.0025-0.005mm thick), ready for most tooling applications | Stamping dies, mold inserts, functional components |
Wire-Cut (Multi-Pass) | Multiple trim passes for superior surface finish (Ra 0.4μm or better) | Precision punches, cosmetic surfaces, low-friction applications |
Lapping/Polishing | Manual or machine polishing to mirror finish | Mold cavities, optical components, high-wear surfaces |
Custom Finishes | Per your specification | Specialized requirements |
Specification | Our Standard Capability |
Maximum Workpiece Size | Up to [1000mm x 800mm x 400mm] |
Maximum Workpiece Weight | Up to [100kg] |
Wire Diameter Range | 0.10mm – 0.30mm (standard 0.25mm) |
Standard Tolerance | ±0.005mm |
Precision Tolerance Capability | ±0.002mm achievable with CMM verification |
Surface Finish (Standard) | Ra 1.2 μm – 1.6 μm (as-EDMed, single pass) |
Surface Finish (Multi-Pass) | Ra 0.2 μm – 0.4 μm (4-pass trim) |
Taper Angle Capability | Up to ±30° (dependent on workpiece thickness) |
Minimum Internal Corner Radius | 0.05mm – 0.10mm (wire radius dependent) |
Maximum Workpiece Thickness | Up to [400mm] |
Our Wire EDM capabilities are essential for producing high-quality rotational components across diverse sectors:
Need parts for a different industry? Contact us to discuss your specific application.
Industry | Typical Parts |
Tool & Die | Stamping dies, progressive die sets, punch holders, die plates, forming tools |
Injection Molding | Mold inserts, core pins, ejector pin holes, cooling channel features |
Aerospace | Turbine blade cooling holes, fuel system components, actuator parts |
Medical | Surgical cutting tools, implantable device prototypes, micro-instruments |
Automotive | High-strength stamping dies, transmission components, sensor housings |
Electronics | Lead frames, connector pins, precision contacts, IC lead frames |
Yes. We support from 1 prototype to high-volume production. No minimum order quantity (MOQ) for custom EDM parts.
Absolutely. We specialize in custom non-standard EDM machining for complex geometries, sharp corners, and unique material requirements.
Rapid prototyping: 5-7 business days for most materials. Expedited options available.
Yes. We are an OEM manufacturer based in Shenzhen, serving automotive, medical, aerospace, and electronics industries worldwide.
Every part undergoes CMM inspection. We provide full dimensional reports and material certifications upon request.
STEP, IGES, STL, SLDPRT, X_T, and DWG. For best results, we recommend STEP or IGES files for 3D models.
Have a project in mind? Upload your CAD file and our engineering team will review it within 24 hours.
