Precision Wire EDM Services
Electrical Discharge Machining (EDM) is an advanced machining process that relies on the precise application of an electrical spark to achieve the desired workpiece shape or surface finish. Wire EDM (WEDM) is a variation of the EDM machining method and is often used to cut sheet metal or form cable ties, tools or punches from harder metals that are not typically suitable for standard machining processes.
Pentek is committed to providing the highest quality wire EDM services for your project needs. Our team of experts has extensive experience in producing high-quality, complex parts using this high-precision, efficient method. Contact us today to learn more or schedule a consultation!
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.
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.
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!
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.
WIRE EDM MATERIALS
Pentek 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
Pentek 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
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.
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
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.
Electrical Discharge Machining Process
The EDM manufacturing process begins by immersing an electrode wire in a dielectric fluid, typically deionized water. An electrical current is then passed through the wire, creating a voltage between the wire and the workpiece. Tiny electrical sparks erode the material between the workpiece and the wire.
Wire EDM services utilize this precise method to produce high-quality, precise, and tight-tolerance parts. The process is ideal for producing parts with complex shapes, sharp corners, and fine features that are not possible with traditional machining methods.
What are the advantages of using a wire EDM machine?
Wire EDM offers a range of important benefits in the manufacturing process. These include:
High precision: Wire EDM machines can achieve tolerances as tight as ±0.0001 inches, enabling precision parts to be manufactured with extreme accuracy.
Efficient production: The non-contact nature of the process reduces the risk of tool wear and allows for continuous cutting, which reduces production time.
Versatility: Wire EDM can be used on a wide range of materials, including conductive and non-conductive metals, making it suitable for a wide range of applications.
Cost-effective: When high precision is required or the material being machined is hard or exotic, the accuracy and efficiency of wire EDM can result in significant cost savings compared to traditional machining methods.
Wire EDM
In addition, this EDM process is able to achieve precise, burr-free surface and edge finishes. This means that parts typically require minimal post-processing and can move directly to the next stage of production, reducing overall lead time.
Many manufacturers also choose wire EDM services because of its fast turnaround time. This allows you to receive finished parts quickly, minimizing unproductive downtime. If cost is a major consideration, wire EDM is more affordable than many other machining processes. It is also a great choice if you frequently use “exotic” materials in your manufacturing process, such as tungsten carbide, super alloys, or medical-grade stainless steel. These materials are easier to shape with wire EDM than with other methods.
Wire EDM Service Applications
Wire EDM services are suitable for mold making processes and are increasingly used to make prototypes and production parts. The process can also be used to machine hard materials that are difficult to machine with other processes.
Wire EDM is widely used in various industries such as aerospace, automotive, medical and electronics due to its high precision and versatility. Some common applications include:
Injection molds
Extrusion molds
Stamping molds
Prototype production
Medical devices
In general, EDM machining services are well suited to machining parts with very thin walls because the contact surface and forces are evenly distributed, and the workpiece will not deform. EDM also performs well when machining deep or narrow cavities. Wire EDM can produce complex shapes that cannot be achieved with traditional machining methods.
In addition, EDM machining is well suited for applications that require multiple component assembly because it can create a single workpiece by machining tapers or grooves.
