Sinker EDM Machining



Machining the Impossible – Sinker EDM Services

EDM Intelligent Solutions offers cutting-edge CNC Sinker EDM (Electrical Discharge Machining), also known as Die Sinking EDM, Conventional EDM, Plunge EDM or Ram EDM. Sinker EDM enables the creation of intricate shapes without inducing stress into electrically conductive materials. It offers a safe machining solution for complex parts, including those that have undergone prior machining processes. This non-contact machining process is ideal for applications aiming to minimize machining risk and achieve unparalleled accuracy and reliability.

Differences Between Sinker EDM and 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 never touches the machined material.

However, unlike Wire EDM, Sinker EDM does not necessarily cut through the entire material unless required, resulting in a broader range of applications like blind cavities/keyways, cross-sections, and thin walls. This adaptability makes it particularly useful for manufacturing components of injection molds and stamping dies. Our extensive selection of EDM generator technologies delivers top-tier surface finishes across diverse materials.

By cultivating strong relationships with our technology partners, we continuously refine our Sinker EDM capabilities, ensuring we stay ahead of the curve and deliver innovative solutions for our customers. EDM Intelligent Solutions provides prototyping, production, and contract manufacturing Sinker EDM services. We will work with you to provide the best solution to your most difficult EDM project requirements.

Sinker EDM Capabilities

Sinker EDM services are integral to the history of EDM Intelligent Solutions. For 25 years, we have offered standard tolerances (0.0010 inches to 0.0005 inches) and high-precision tolerances as tight as 0.0001 inches  (2 microns) for various industries and applications. Our 4-axis CNC Sinker EDM machines produce complex shapes with extreme consistency and can run electrodes made from many materials.

Our in-house electrode machining department is built to run 24/7 with integrated robotic machine tending. This ensures that our Sinker EDM productions are never left waiting for the arrival of finished electrodes from outside suppliers. This keeps all Die Sinking EDM projects running throughout the day and into our lights-out night shift.

We achieve extreme machining efficiencies by fixturing and burning multiple parts simultaneously using multi-up electrodes. This process produces identical components in a single machining cycle, significantly boosting productivity and saving our customers time and money. Our decades of experience in EDM machining and state-of-the-art equipment enable us to deliver consistently high-quality parts and components from any 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 Ram EDM services with other manufacturing offerings like Precision Grinding and Micro Milling and 3D Measurement of machined components for full quality assurance.

Sinker EDM Manufacturing Specifics:

    • State-of-the-art 4-axis CNC Sinker EDMs engineered for efficient 24/7 operation
    • Multiple sinker electrode materials are used like brass, copper, graphite and tungsten
    • Machining of workpieces up to 12 inches thick
    • Multi-up Sinker EDM techniques for simultaneous machining of multiple parts
    • High-precision tolerances as tight as 0.0001 inches  (2 microns) and standard machining tolerances from 0.0010 inches to 0.0005 inches
    • Micromachining tolerances of 1 micron and below
    • Finished feature sizes as small as 40 microns
    • Feature aspect ratios up to 38:1
    • Micro EDM drilled hole diameters as small as 40 micrometers (µm)
    • Precise finishes as low as 4Ra µin (micro inches) alleviate the need for additional finishing or polishing
    • Small batches of 1-50+ components
    • 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 is dedicated to fulfilling your specific requirements. By leveraging strategic sourcing partnerships with a diverse network of qualified material suppliers nationwide, we can manufacture your components from the precise materials you need. This facilitates timely delivery and eliminates any potential roadblocks related to material availability.

All vendors and material suppliers to EDM Intelligent Solutions meet strict quality standards to ensure that the components we produce meet the highest standards commonly required by the aerospace, automotive, communications, defense, medical and scientific industries.

Regarding materials, Sinker EDM is compatible with numerous metals unsuitable for conventional machining, like milling and turning. The Sinker EDM erosion process effectively machines hardened materials like tungsten carbide. Sinker EDM electrodes gently shape softer materials such as copper, while extremely thin materials are protected from damage and precisely machined since the electrode does not touch the workpiece.

Sinker EDM Compatible Materials

EDM Intelligent Solutions has completed thousands of Sinker EDM projects using diverse materials, such as those listed below:

  • 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

Please contact us if your specific material does not appear on the list. We will help determine if it can be machined using our CNC Electrical Discharge Machining and assist you in sourcing the material.

Common Wire EDM Applications

When your components need deep cavities, blind cuts and/or the addition of screw threads, Sinker EDM machining is the ideal solution. Die Sinker EDM Services are well suited for parts requiring intricate tolerances, superior surface roughness finishes and those with material stress and thermal heating limitations.

Sinker EDM can also 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 the design requires materials that are too brittle. By utilizing multi-up Sinker EDM processing, we can efficiently scale the simultaneous production of parts to meet the high-volume demands of our largest customers.

This represents only a fraction of the diverse components that EDM Intelligent Solutions has manufactured using our advanced Wire EDM machining techniques. Over the past 25 years, we have tackled almost every type of part across numerous industries.

At EDMIS, no project is too large, no part too intricate and no tolerance too tight. This commitment to precision and scalability makes us the go-to partner for OEM manufacturers nationwide. To learn more about how EDMIS can help you, contact our manufacturing team with your request for a 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 throughout the country, including SLAC National Accelerator Laboratory.

Competitive Electrical Discharge Machining Solutions

As our name implies, Sinker EDM is one of our core services. Over the past 25 years, we have successfully completed thousands of projects. What sets our manufacturing services apart is our ability to maintain micron tolerances while offering competitive pricing and unparalleled lead times.

Get a Quote for Sinker EDM Services

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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