Machining

Wire EDM

Wire EDM machining services for intricate profiles, sharp corners, and detailed features in conductive materials.

Machining
Sodick wire EDM with the wire spool and upper guide head above its tank
Overview

Precision wire EDM services for complex profiles and detailed features

Wire EDM, also known as wire cut EDM or wire electrical discharge machining, is an EDM process that uses a thin wire to cut profiles by removing material from electrically conductive workpieces through controlled electrical discharges rather than physical cutting force. The wire and workpiece sit in a dielectric fluid, typically deionized water, which controls each spark and flushes away debris as it cuts. This produces tight tolerances and clean surface finishes on intricate contours, fine details, and sharp corners, including hard or heat-resistant materials that are difficult to machine conventionally.

6
Wire EDM machines
13.5" × 20.5" × 16"
Maximum work envelope
No cutting force
Material removal method
Equipment‍

Equipment and technical specifications

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Equipment Type
Manufacturer
Model
Part Window · Technical Specs
Wire EDM
Charmilles
Robofil 290
9.5" x 15" x 7.5"
Wire EDM
Charmilles
Robofil 310
10" x 16" x 10"
Wire EDM
Charmilles
Robofil 330F
11" x 15" x 15"
Wire EDM
Charmilles
Robofil 440 cc
13.5" x 20.5" x 16"
Wire EDM
Charmilles
Roboform 350S
—
Wire EDM
Sodick
AQ360LX
—

Equipment shown is representative of what supports this capability. Contact us for more information or to confirm we can support your project.

Products

Products and components we manufacture

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Machine bases

Large structural bases for custom machinery and industrial equipment.

Weldments

Custom welded structures produced to drawing requirements.

Fixturing

Custom fixtures and tooling for production applications.

Housings

Custom housings produced to customer drawings and specifications.

Shafts

Precision shafts for rotating equipment and mechanical systems.

Plates

Custom machined plates, including large-format components.

Materials we work with

A wide range of metals, machined in-house

From common steels and aluminum to high-temperature and exotic alloys, we regularly machine a broad range of materials for demanding programs.

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Stainless Steel

Stainless Steel · Precipitation-Hardening Stainless Steel

Carbon & Alloy Steel

Carbon Steel · Alloy Steel · HSLA Steel

Aluminum

Aluminum alloys

Titanium

Titanium alloys

Nickel & High-Performance Alloys

Nickel Alloys · Inconel

Copper, Brass & Bronze Alloys

Copper · Brass · Bronze · Aluminum Bronze · Silicon Bronze

Specialty & Exotic Materials

Specialty Alloys · Exotic Metals

Quality & Inspection

Quality built into the process

We approach every project with a commitment to precision, consistency, and workmanship.

.0001"
Inspection capability
CMM
Precision Inspection
144" x 48"
Granite inspection surface

Process control

In-process checks help keep work aligned with drawings and specifications through final inspection.

Precision inspection

CMMs, optical comparators, and manual gaging help verify critical dimensions and complex part geometry.

Material traceability

Material traceability is maintained throughout production to support regulated work and audit readiness.

Documentation & compliance

Quality records are managed alongside production to support customer, compliance, and program needs.

Industries We Serve

Manufacturing for the most demanding industries

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Turbofan engine on aircraft wing

Aerospace

Aerospace

Flight-critical parts machined to spec with the documentation programs demand.

Modern military fighter jet on the flight line

Defense & Military

Defense & Military

ITAR-compliant work for defense programs, from prototype to sustained production.

Stainless steel process piping and valves

Commercial Nuclear

Commercial Nuclear

Nuclear-grade work delivered through our partnership with Trust Manufacturing.

Industrial robot arm on an automation assembly cell

Machine Builders

Machine Builders

Complex components and assemblies for custom equipment and machine builds.

All capabilities

Explore our manufacturing capabilities

See our full range of in-house manufacturing capabilities that support complex, multi-step work from start to finish.

FAQs

Frequently asked questions

Have questions? Here are answers to some of the questions we hear most often.

What are the advantages of wire EDM?

Wire EDM offers several advantages over conventional machining methods. Because material is removed through electrical discharge rather than physical cutting force, the process avoids mechanical stress and produces virtually burr-free edges, reducing the need for secondary deburring. It also holds tight tolerances and fine surface finishes on hard or heat-resistant materials that are difficult to machine conventionally, and it can produce intricate contours and sharp internal corners that other cutting methods cannot reach.

Can wire EDM be combined with other machining processes?

Yes. Wire EDM can be coordinated with CNC milling, CNC turning, sinker EDM, grinding, and inspection within the same facility. This allows a part to move between processes without being sent to an outside EDM supplier.

What materials can be cut with wire EDM?

Wire EDM works on any electrically conductive material and is commonly used on hard or heat-resistant alloys that are difficult to cut conventionally, supporting a wide range of materials from tool steels to exotic alloys. Because the wire never contacts the part with cutting force, it can hold tight tolerances on delicate or hardened features.

What is the maximum wire EDM work envelope?

Our wire EDM equipment supports work envelopes up to 13.5" x 20.5" x 16". Final part fit and cutting speed depend on the complete part geometry, material, and required tolerances, so request a quote with your part drawing to confirm capacity.

What types of parts are a good fit for wire EDM machining?

Wire EDM machining is well suited for parts with intricate cut profiles, fine details, sharp corners, and other features difficult to achieve with conventional cutting. A thin, moving wire and controlled electrical discharges cut through electrically conductive material without contact force, delivering high precision and holding tight tolerances on delicate features.

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