Sinker EDM Machining



Machining The Impossible  – Sinker EDM Services

EDM Intelligent Solutions specializes in CNC Sinker EDM (Electrical Discharge Machining), also referred to as Conventional EDM, Die Sinking EDM, Plunge EDM or Ram EDM. Sinker EDM offers the ability to produce complex shapes without inducing stresses into the electrically conductive material and provides low-risk machining solutions for complex components and parts with previous machining already completed. This non-contact machining process is ideal when looking to minimize machining risk and achieve unparalleled accuracy and reliability.


What’s the difference between Sinker EDM & Wire EDM?

Electric current is used to cut or burn away conductive materials in both Wire EDM and Sinker EDM. In both processes, the electrode doesn’t ever touch the material being machined. Unlike Wire EDM, Sinker EDM services do not cut completely through the material (unless desired), resulting in a wider variety of applications, such as blind cavities/keyways, thin walls, or cross-sections. This versatility makes sinker EDM an efficient technology for components of stamping dies and injection molds. Our vast library of EDM generator technologies offers the best surface finishes available in a multitude of materials. By maintaining strong and ongoing relationships with our technology partners we are able to stay on the forefront of Sinker EDM capabilities and meet the ever-evolving needs of our customers. EDM Intelligent Solutions provides prototyping, production, and contract manufacturing Sinker EDM services. We will work with you in providing the best solution to your most difficult EDM project requirements.


Sinker EDM services are integral to the history of EDM Intelligent Solutions. For 25 years we have been offering standard tolerances (0.0010″ to 0.0005″), as well as high precision tolerances as tight as 0.0001″ (2 micron) for an array of industries and applications. Our 4-Axis CNC Sinker EDM machines produce complex shapes with extreme consistency and have the capacity to run electrodes made from a multitude of materials. Our in-house electrode machining department is built to run 24/7 with integrated robotic machine tending which ensures that our Sinker EDM machines are never left waiting for finished electrodes to arrive from outside suppliers. This keeps all Die Sinking EDM projects running throughout the day and into our lights out night shift. Extreme machining efficiencies are possible using Sinker EDM when multiple parts are fixtured and burnt simultaneously using multi-up electrodes producing multiple identical components in the same machining cycle. This instantly multiplies productivity and saves our customers’ time and money. Our decades of EDM machining experience and state-of-the-art equipment enable us to provide repeatable quality parts and components from any type of conductive material.

We are continuously working with our technology partners to upgrade our CNC sinker EDM machining capabilities to meet the ever-evolving needs of our diverse base of customers. We also complement our sinker EDM capabilities with other manufacturing services like Precision Grinding and Micro Milling, as well as 3D measurement of machined components for full quality assurance.

Sinker EDM Manufacturing Specifics:

  • Advanced 4-Axis CNC Sinker EDMs built for efficient 24/7 operation
  • Multiple sinker electrode materials are used like brass, copper, graphite and tungsten
  • Workpieces up to 12″ thick are easily machined using Sinker EDM
  • Simultaneous machining of multiple parts using multi-up Sinker EDM techniques
  • Standard machining tolerances of 0.0010″ to 0.0005″ and high precision tolerances as tight as 0.0001″ (2µm micron)
  • Micromachining Sinker EDM tolerances of 1µm and below
  • Finished feature sizes as small as 40µm
  • Feature Aspect Ratios up to 38:1
  • Fine (micro) EDM drilled hole diameters as small as 40µm
  • Surface Finishes down to 4Ra µin (micro inch) eliminate finishing and require no additional polishing
  • Small quantities of 1-50+ pieces
  • Contract Manufacturing of full production quantities of thousands of pieces

Have a new Sinker EDM project that you want to discuss? We are here to support you, call us today at 630.736.0531 or Request a Quote!

Sinker EDM - EDM Department Inc

Sinker EDM Materials

EDMIS strives to meet your specific needs. Through strategic sourcing partnerships with a vast array of qualified material suppliers nationwide, we can manufacture your components from the exact materials that you require. Strict quality standards are met by all vendors and material suppliers to EDM Intelligent Solutions to ensure that the components we produce can meet the highest standards commonly required by the Aerospace, Automotive, Communications, Defense, Medical and Scientific industries.

When it comes to materials, Sinker EDM is compatible with a large range of metals that conventional machining, like milling and turning, are not always cut out for. Hardened materials like tungsten carbide are no match for the sinker EDM erosion process. Softer materials like copper are gently shaped by the Sinker EDM electrodes and extremely thin materials are protected from damage and accurately machined since the electrode never actually makes contact with the workpiece.


Sinker EDM Compatible Materials

EDM Intelligent Solutions has completed thousands of Sinker EDM projects using a diverse set of materials including those listed below. Don’t see your specific material on the list? Contact us to determine if that material can be cut using CNC Electrical Discharge Machining and how EDMIS can source that material for you.

  • Aluminum
  • Brass
  • Copper
  • Exotic Metals
  • Molybdenum
  • Titanium
  • Tungsten
  • Carbide
  • Tool Steels
  • A-2, A-5, A-6, A-8
  • D-2, D-3, D-5
  • DC-53
  • H-11, H-12, H-13, H-19
  • L-6
  • M-1, M-2, M-3, M-4, M-42
  • O-1, O-6
  • S-1, S-7
  • T-1


When components require deep pockets, blind cuts, and/or screw threads to be added, Sinker EDM machining should be considered. Sinker EDM services are well suited for parts requiring intricate tolerances, the limitation of material stress and thermal heating, and those needing superior surface roughness finishes. Sinker EDM can also be used to clear broken taps, remove broken cutting tools, and clean out damaged holes without affecting the hole’s geometric position. Die sink spark erosion machining can also be a high-volume alternative to traditional CNC machining methods when materials that are too brittle are required by design. Through multi-up sinker EDM processing, the quantities of parts being burnt simultaneously can easily be scaled up to meet the high volumes required by some of our largest customers.

This is just a small sample of all the types of components that EDM Intelligent Solutions has manufactured using our advanced Wire EDM machining processes. There really aren’t many types of parts that EDMIS has not worked on in some form over the last 25 years serving these industries. No project is too big or part too complex or tolerance too tight for EDM Intelligent Solutions which makes us the preferred partner for OEM manufacturers nationwide. To learn more about how EDMIS can help you contact our manufacturing team with your request for quote.

Sample Sinker EDM Applications

  • Interconnect Components
  • Fiber Optic Components
  • Medical Components
  • Optical Lenses
  • Research & Development
  • Aerospace Industry
  • Defense Industry
  • Digital Manufacturing & Design Innovation Institute (DMDII)
  • Nationally Ranked Universities
  • Research Labs through the country, ex: SLAC National Accelerator Laboratory.

Competitive Electrical Discharge Machining Solutions

As our name suggests, Sinker EDM is one of our main service offerings. Over the past 25 years, we’ve completed thousands of Sinker EDM projects. What differentiates EDM Intelligent Solutions manufacturing services from the competition is our ability to not only hold micron tolerances but to do so while still offering globally competitive pricing and lead times. Utilizing our vast knowledge of Sinker EDM techniques and decades of industry experience, we are confident that we can produce your most challenging components to your exact specifications. To learn more about how EDMIS can help you, contact our manufacturing team with your request for a Die Sinking EDM quote.


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