Wire EDM Machining



Machining the Impossible – Wire EDM Services

CNC Wire cutting EDM services are what we do best. We offer standard, as well as high precision tolerances, as tight as 2µm (0.0001″) for an array of industries and applications. Our wire cut electrical discharge machinery have the capacity to run multiple wire sizes, including small wire EDM and microwire as small as 20µm (0.0008″) in diameter. Our experience and state-of-the-art wire EDM cutting equipment enable us to provide accurate, repeatable, and quality parts and components made from nearly any type of conductive material. Complex shapes with small features and tight tolerances in materials that make traditional CNC machining almost impossible are easily achieved using Wire EDM machining. The small wire EDM processes unique to EDM Intelligent Solutions even allow for the creation of wire EDM finished holes with diameters as small as 30 microns.


What is Wire EDM?

The Wire EDM (Electrical Discharge Machining) process uses a thin single strand of wire, which is fed through the workpiece in conjunction with high pressure deionized water. Multiple miles of wire electrode held on wire spools is fed between two guide rollers, much like the blade on a band saw, that are then driven in a path controlled by the CNC machine control. During this EDM metal cutting process, electric current is used to erode away the conductive materials of the workpiece and leave behind an extremely smooth and uniform surface that requires no additional finishing or polishing processes. This wire electrical discharge machining process is typically used when low residual stresses in the workpiece material are desired, as there is little change to the mechanical properties of the material. During this process, the cutting wire electrode doesn’t ever touch the workpiece material. Instead, the EDM cutting takes place when electrical sparks form between the material and the cutting wire in what is referred to as the voltage gap. Highly filtered, deionized water is used because it deionizes the spark gap, flushes away the metal particles removed by erosion from the workpiece, and acts as a cooling medium to keep the machining temperatures stable. Wire EDM machining is widely used within a multitude of industries for creating components by cutting intricate shapes in numerous conductive and oftentimes delicate materials.

Wire EDM Cutting Metal

Wire EDM Capabilities

Wire EDM services are what we do best. We offer standard tolerance of (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 5-Axis CNC wire cut EDM machines offer superior cutting consistency and have the capacity to run multiple wire electrode sizes, including microwires as small as 0.0008″ (20 micron) in diameter. Extreme machining efficiencies are possible using Wire EDM Cutting when multiple parts are stacked and cut simultaneously. Certain part geometries allow for simultaneous cutting of stacked sheets of materials the produces 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 wire EDM machining capabilities to meet the ever-evolving needs of our diverse base of customers. We also complement our Wire Electrical Discharge Machining capabilities with other manufacturing services like Precision Grinding and Micro Milling, as well as 3D measurement of machined components for full quality assurance.


Wire EDM Manufacturing Specifics:

  • Advanced 5-Axis CNC Wire EDMs built for efficient 24/7 operation
  • Multiple wire electrode sizes from 0.0120″ down to as small as 20um (0.0008″) in diameter
  • Multiple wire electrode materials are used like brass, copper, molybdenum and tungsten
  • Extremely consistent cut quality due to the wire electrode being cycled between spools during the cutting process
  • Workpieces up to 8″ thick are easily machined using Wire EDM
  • Simultaneous machining of multiple parts using stacked Wire EDM techniques
  • Standard machining tolerances of 0.0010″ to 0.0005″ and high precision tolerances as tight as 0.0001″ (2µm micron)
  • Micromachining Fine Wire EDM tolerances of 1µm and below
  • Wire EDM finished 30 micron diameter holes
  • Feature Aspect Ratios up to 38:1
  • Surface Finishes down to 4Ra µin (micro inch) eliminate finishing and require no additional polishing
  • Small quantities of 1-50+ pieces with quick turnarounds
  • Contract Manufacturing of full production quantities of thousands of pieces


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

Precision Wire EDM Services for Prototyping & Production


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, Wire 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 wire EDM erosion process. Softer materials like copper are gently shaped by the Wire EDM electrodes and extremely thin materials are protected from damage and accurately machined since the wire never actually makes contact with the workpiece.


Wire EDM Compatible Materials

EDM Intelligent Solutions has completed thousands of Wire 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
  • 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
Precision Wire EDM Services for Prototyping & Production

Common Wire EDM Applications

When components require cuts made through the entire thickness of the raw material, Wire EDM machining should be considered. Wire 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. Wire spark erosion machining can also be a high-volume alternative to die stamping when material that are too brittle to be stamped are required by design. Through stacked wire EDM processing the quantities of parts being cut 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 with your EDM Metal Cutting project, contact our manufacturing team with your request for quote.


Sample Wire EDM Applications

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

Competitive Electrical Discharge Machining Solutions

As our name suggests, Wire Electrical Discharge Machining is one of our main service offerings. Over the past 25 years, we’ve completed thousands of Wire 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 Wire 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 with your Wire EDM Cutting project, contact our manufacturing team with your request for quote.


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