Wire EDM Machining Services.
Electrical discharge machining for intricate cuts in conductive materials with exceptional accuracy and smooth surface finishes.
Precision Wire EDM
Ultra-precise cutting for complex geometries and tight tolerances.
Hard Material Machining
Machine hardened materials without affecting material properties.
Intricate Features
Create complex internal features and sharp corners impossible with conventional machining.
What Is Wire EDM?
Wire EDM (Electrical Discharge Machining), also known as wire cutting or wire erosion, is a precision machining process that uses a thin, electrically charged wire to cut through conductive materials. The wire never physically touches the workpiece; instead, electrical sparks erode the material to create the desired shape.
Wire EDM is ideal for cutting intricate shapes, sharp corners, and complex contours in hardened materials without inducing mechanical stress or heat-affected zones. The process can achieve tolerances as tight as ±0.0001" (±0.0025mm) with excellent surface finishes.
Xofah's wire EDM services provide access to state-of-the-art EDM machines capable of producing parts from prototype quantities to production runs. Our network of certified machine shops specializes in precision tooling, medical devices, aerospace components, and other applications requiring extreme accuracy.
Ultra-Precision
Tolerances as tight as ±0.0001" (±0.0025mm)
Excellent Finish
Surface finish Ra 8-32 µin (0.2-0.8 µm)
Hard Materials
Machine hardened steel, carbide, and exotic alloys
Complex Shapes
Sharp corners, narrow slots, intricate contours
Operational Logic
Wire EDM Process
Wire EDM uses electrical sparks to erode material from a conductive workpiece. The process is highly controlled and produces no mechanical stress on the part.
How Wire EDM Works
Key Process Characteristics
Wire EDM Capabilities
4-Axis Wire EDM
U-V axes allow tapered cuts and complex 3D shapes
Submerged Cutting
Entire workpiece submerged for better accuracy and finish
Automatic Wire Threading
Automatic wire threading for multiple cutouts
Skim Cutting
Multiple finishing passes for superior surface finish
| Specification | Standard | High-Precision |
|---|---|---|
| Maximum Part Size | 24" x 16" x 12" | 12" x 8" x 8" |
| Maximum Part Weight | 1000 lbs | 500 lbs |
| Maximum Thickness | 12" (305mm) | 8" (203mm) |
| Minimum Feature Size | 0.004" (0.1mm) | 0.002" (0.05mm) |
| Standard Tolerance | ±0.0005" (±0.013mm) | ±0.0002" (±0.005mm) |
| Tight Tolerance | ±0.0002" (±0.005mm) | ±0.0001" (±0.0025mm) |
| Surface Finish | Ra 32 µin (0.8 µm) | Ra 8 µin (0.2 µm) |
| Corner Radius | 0.004" (0.1mm) | 0.002" (0.05mm) |
| Taper Capability | ±15° per side | ±30° per side |
| Typical Lead Time | 5-7 days | 7-10 days |
Wire EDM Materials
Wire EDM can cut any electrically conductive material, regardless of hardness. This makes it ideal for machining hardened tool steels, carbides, and exotic alloys.
Common Materials
Material Requirements
Design Guidelines for Wire EDM
Follow these guidelines to optimize your parts for wire EDM and achieve the best results.
Starting Holes Required
Internal cutouts require a starting hole (typically 0.125" diameter) for wire threading
Minimum Corner Radius
Internal corners will have radius equal to wire diameter plus spark gap (typically 0.004"-0.008")
Avoid Thin Walls
Walls thinner than 0.020" may be difficult to hold and may warp
Consider Taper
Specify taper angle if needed for draft or clearance
Material Thickness
Thicker materials take longer to cut and may have reduced accuracy
Surface Finish
Specify required surface finish - finer finishes require more passes
Applications
Wire EDM is used across industries for applications requiring extreme precision and the ability to machine hardened materials.
Stamping Dies
Precision dies for sheet metal stamping
Injection Mold Tooling
Mold inserts and core pins
Extrusion Dies
Dies for aluminum and plastic extrusion
Punch and Die Sets
Precision punches and dies
Gears and Splines
Precision gears in hardened steel
Prototype Parts
Complex prototypes in production materials
Advantages of Wire EDM
Wire EDM vs. Conventional Machining
| Feature | Wire EDM | Conventional Machining |
|---|---|---|
| Hardened Materials | Excellent - any hardness | Difficult - limited by tool hardness |
| Precision | ±0.0001" possible | ±0.001" typical |
| Surface Finish | Ra 8-32 µin | Ra 32-125 µin |
| Internal Corners | Sharp (0.002" radius) | Limited by tool radius |
| Thin Walls | Excellent - no pressure | Difficult - tool pressure |
| Complex Contours | Excellent | Limited |
| Material Stress | None | Can cause distortion |
| Speed | Slower | Faster for simple shapes |
| Cost | Higher for simple shapes | Lower for simple shapes |
| Material Requirement | Must be conductive | Any material |
Get Started with Wire EDM
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