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Fine Wire EDM

Micro Miniature Fine Wire EDM Services for Contract Manufacturing

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MACHINING THE IMPOSSIBLE – FINE WIRE EDM SERVICES

Micro CNC Wire cutting EDM services are what we do best. We offer ultra-precision tolerances, as tight as 1µm, for an array of industries and micromanufacturing applications. Our fine wire cut electrical discharge machinery have the capacity to run multiple wire sizes, including microwire as small as 20µm (0.0008″) in diameter. Our experience and state-of-the-art equipment enable us to provide accurate, repeatable, and quality parts and components made from any type of conductive material.

 

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 deionized water. The wire is spooled between two guide rollers, much like the blade on a band saw, that are guided in a path controlled by the CNC. During this process, electric current is used to cut away the conductive materials of the workpiece and leave behind a smooth surface that requires no additional finishing or polishing processes. This process is typically used when low residual stresses are desired as there is little change in the mechanical properties of the material. During this process, the cutting wire doesn’t ever touch the material. Instead, the cutting takes place when sparks form between the material and the cutting wire. Deionized water is used because it deionizes the spark gap, flushes away the particles removed from the workpiece, and acts as a cooling medium. 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.

Fine Wire EDM Capabilities

Wire EDM micromachining utilizing micro diameter wire electrodes is the next leap forward in technology for ultra-precision machining and surface finish capability of micro-manufacturing operations that require CNC Wire EDM. EDM Intelligent Solutions EDM Hole Drilling machines are used to first drill miniature holes, sometimes as small as 30 microns (0.0010″) in diameter, to allow fine wire electrode sizes ranging from 100 microns (0.0040″) down to 20 microns (0.0008″) in diameter to be threaded through the workpiece. Micron level feature accuracy, improved overall part accuracy, superior surface finish, and unmatched metallurgical quality is achieved through the use of cutting edge EDM generator technologies and electrode materials. Surface finishes down to as low as 4Ra microinch are easily achieved without the need for polishing using fine Wire EDM micro-cutting techniques.

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 EDM capabilities with other manufacturing services like Precision Grinding and Micro Milling, as well as 3D measurement of machined components for full quality assurance.

 

Fine Wire EDM Manufacturing Specifics:

  • Advanced 5-Axis and 6-Axis CNC Wire EDMs built for efficient 24/7 operation
  • Multiple wire electrode sizes from 100 microns (0.0040″) 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 2″ thick are easily machined using Wire EDM
  • Simultaneous machining of multiple parts using stacked Wire EDM techniques
  • 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

WIRE 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, 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

Common Fine 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. Typical projects that are completed through the use of fine Wire EDM are for micro-manufacturing ultra-precision applications such as components for fiber optics, miniature and micro connectors, medical and surgical instruments, micro gears and micro plastic injection molding.

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 Fine 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
MICRO MINIATURE FINE WIRE EDM SERVICES FOR CONTRACT MANUFACTURING

Competitive Electrical Discharge Machining Solutions

As our name suggests, Wire EDM 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 contact our manufacturing team with your request for quote.

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