Advanced Wire EDM Machining Solutions
Wire EDM is critical for tool & die, medical, and aerospace sectors requiring micron-level precision. Key applications:
- Mold base insert fabrication
- Surgical instrument blanks
- Gear cutting electrode tools
- Turbine blade slot cutting
- Automotive stamping dies
- Semiconductor wafer guides
Start A New Wire EDM Quote
Start to Upload Your Files
Drag and drop file here or click the button below or
STEP | STP I SLDPRT I IPT I PRT I SAT FLES
STEP | STP I SLDPRT I IPT I PRT I SAT FLES
All uploads are secure and confidential.
Service
-
High-Speed Wire EDMFeatures reciprocating wire movement at 8–10 m/s. The wire can be reused, offering high efficiency but lower accuracy (±0.02 mm). Commonly used for mid-to-low-end mold machining. -
Low-Speed Wire EDMEmploys disposable electrodes with ≤0.2 m/s unidirectional feed, delivering ultra-high precision (±0.002 mm) and superior finish (Ra < 0.4 μm) for aerospace components, though requiring costly equipment. -
Mid-Speed Wire EDMCombines high-speed roughing (strong discharge) with low-speed finishing (weak currents) in multi-pass cutting, achieving balanced efficiency and surface quality (Ra 1.6–0.8 μm). -
Precision Wire EDM ServiceDelivers micron-level accuracy (±0.002mm) via CNC machining and multi-stage processing, ensuring superior finishes (Ra <0.4μm) for aerospace/medical components with fast turnaround.
Our High-Precision Wire EDM Parts
Utilizing AgieCharmilles CNC wire EDMs, we cut conductive materials (0.1-300mm thickness) with 0.005mm accuracy and Ra 0.4μm finish. Ideal for hardened tool steels, titanium, and carbide components requiring sharp corners, micro holes, or intricate geometries without thermal distortion
Wire EDM Materials
Precision-cutting hardened steels (D2, M2) up to 300mm thickness with 0.02mm accuracy. Special brass wire technology for intricate geometries in tungsten carbide and titanium alloys for mold components and aerospace parts.
Metals
Lightweight, high thermal conductivity, Excellent Machinability, Superior Dimensional Stability, Tight-Tolerance Capable, Perfect for Complex CNC Milling and Turning.
Price: $0
Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Price: $0
Lead Time: < 5 days
Tolerances: ±0.005″ (±0.125mm)
Max part size: 200 cm x 80 cm x 100 cm
Golden aesthetic, good machinability, moderate corrosion resistance, often used for decorative hardware.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Superior wear resistance, seawater corrosion resistance, classic metallic luster, commonly cast.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
High thermal/electrical conductivity, antimicrobial surface, develops natural patina over time.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
High strength-to-weight ratio, magnetic properties, requires coating for rust prevention.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Chromium-enhanced corrosion resistance, heat-resistant, maintains strength in extreme conditions.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Extremely lightweight (67% aluminum density), good vibration damping, requires surface treatment.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Aerospace-grade strength, biocompatible, seawater corrosion resistance, difficult to machine.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Plastics
Fast-flowing melt, low shrinkage (0.4-0.7%), requires pre-drying (80°C/4h), ideal for automotive dashboards and consumer electronics housings.
Price: $0
Lead Time:
Tolerances:
Max part size:
Price: $0
Lead Time:
Tolerances:
Max part size:
Wire EDM Part Size Standards
Wire EDM Surface Finishes
Looking for the right finish? Choose from 20+ options to meet both your functional and aesthetic needs.
-
As MachinedDescription: Standard finish with surface roughness of 3.2 μm (126 μin), removes sharp edges and deburrs parts cleanly. Key Use: Functional parts requiring no post-processing (e.g., brackets, gears). Process Tolerance: Dimensional ±0.1 mm, Ra 3.2±0.5 μm Process Specifications: ISO 2768-m standard, burr height ≤0.05 mm
-
AnodizingDescription: Electrochemical oxide layer for corrosion resistance and aesthetics. Process Compatibility: Post-machining surface treatment Key Use: Aerospace components, consumer electronics (e.g., phone frames). Process Tolerance: Coating thickness 10-25 μm±2 μm, color consistency ΔE≤1.5 Process Specifications: MIL-A-8625 or ISO 7599, sealing pH 5.5-6.5
-
AlodineDescription: Chemical film for corrosion protection and paint adhesion. Process Compatibility: Post-cleaning chemical immersion Key Use: Aviation and automotive electrical housings. Process Tolerance: Film thickness 0.5-3 μm, visual uniformity Process Specifications: Immersion time 3-10 min, bath temp. 20-30℃
-
Black OxideDescription: Thin magnetite layer for corrosion resistance and reduced glare. Process Compatibility: Post-machining chemical treatment Key Use: Tools, firearms, automotive fasteners. Process Tolerance: Coating thickness 0.5-1.5 μm, salt spray ≥24 hrs Process Specifications: Alkaline bath pH 13-14, process time 5-30 min
-
BrushingDescription: Linear abrasive finish for decorative texture. Process Compatibility: Manual/CNC abrasive belts Key Use: Appliance panels, architectural trims. Process Tolerance: Texture depth 0.05-0.2 mm, angle deviation ≤5° Process Specifications: Abrasive belt grit 80-240, feed speed 10-30 m/min
-
EtchingDescription: Chemical/mechanical removal for micro-texturing or marking. Process Compatibility: Laser/chemical masking Key Use: Circuit boards, decorative logos. Process Tolerance: Etch depth 0.01-0.5 mm±5%, alignment ±0.1 mm Process Specifications: Etchant concentration 10-30%, laser power 20-100 W
-
Electroless PlatingDescription: Uniform metal coating (e.g., nickel) without electricity. Process Compatibility: Chemical bath deposition Key Use: Wear-resistant industrial valves, connectors. Process Tolerance: Coating thickness 5-50 μm±5%, porosity ≤5/cm² Process Specifications: Bath temp. 85-95℃, pH 4.5-5.5
-
ElectroplatingDescription: Electrochemical metal coating (e.g., chrome, zinc) for durability. Process Compatibility: Post-machining electrodeposition Key Use: Automotive trim, jewelry. Process Tolerance: Coating thickness 5-25 μm±2 μm, adhesion ≥4B (ASTM B571) Process Specifications: Current density 1-10 A/dm², bath temp. 40-60℃
-
ElectrophoreticDescription: Polymer coating via electric field for corrosion resistance. Process Compatibility: Post-cleaning immersion Key Use: Automotive frames, HVAC components. Process Tolerance: Coating thickness 15-30 μm±3 μm, edge coverage ≥80% Process Specifications: Voltage 50-300 V, cure 160-200℃×20 min
-
GrindingDescription: Precision abrasive finish for tight tolerances. Process Compatibility: Surface/cylindrical grinding Key Use: Bearing races, hydraulic shafts. Process Tolerance: Dimensional ±0.005 mm, Ra 0.4-0.8 μm Process Specifications: Wheel grit 60-120, coolant flow 5-20 L/min
-
Heat TreatmentDescription: Thermal process to alter material hardness/toughness. Process Compatibility: Post-machining quenching/tempering Key Use: Gears, cutting tools. Process Tolerance: Hardness HRC 45-60±2, distortion ≤0.1% Process Specifications: Quench temp. 800-1000℃, temper time 1-4 hrs
-
KnurlingDescription: Diamond or linear pattern for improved grip. Process Compatibility: CNC lathe rolling Key Use: Handles, adjustment knobs. Process Tolerance: Pattern depth 0.2-0.5 mm, pitch ±0.05 mm Process Specifications: Roller pressure 200-500 N, feed 10-50 mm/min
-
Laser EngravingDescription: Permanent marking via laser ablation. Process Compatibility: Post-processing laser systems Materials: Metals, plastics, wood Key Use: Serial numbers, branding on industrial parts.
-
OvermoldingDescription: Molding soft material (TPU/silicone) over rigid inserts. Process Compatibility: Injection molding Materials: Plastics, metals (as inserts) Key Use: Ergonomic handles, waterproof seals. Process Tolerance: Overmold thickness 1-5 mm±0.2 mm, bond strength ≥5 MPa Process Specifications: Injection pressure >5 MPa, mold temp. 40-80℃
-
PolishingDescription: Mirror-like finish via abrasive compounds. Process Compatibility: Manual/robotic buffing Key Use: Medical instruments, luxury fixtures. Process Tolerance: Ra 0.025-0.1 μm, gloss ≥90 GU Process Specifications: Wheel speed 1000-3000 rpm, compound grit 2000-5000
-
PassivationDescription: Acid treatment to remove free iron and enhance corrosion resistance. Process Compatibility: Post-cleaning chemical immersion Key Use: Surgical tools, food processing equipment. Process Tolerance: Film thickness 0.001-0.01 μm, salt spray ≥96 hrs Process Specifications: Nitric acid 20-50%, process time 20-60 min
-
Powder CoatingDescription: Electrostatic polymer powder cured into durable film. Process Compatibility: Post-cleaning spray and bake Key Use: Outdoor furniture, automotive wheels. Process Tolerance: Coating thickness 60-120 μm±10 μm, ΔE≤1.0 Process Specifications: Voltage 30-90 kV, cure 180-200℃×15 min
-
PhosphatingDescription: Phosphate layer for lubrication and paint adhesion. Process Compatibility: Chemical immersion Key Use: Engine components, firearm parts. Process Tolerance: Coating weight 2-5 g/m², crystal size ≤5 μm Process Specifications: Bath pH 2-4, process temp. 40-70℃
-
PaintingDescription: Liquid coating for color and protection. Process Compatibility: Spraying/dipping Materials: Metals, plastics Key Use: Consumer electronics, automotive body panels. Process Tolerance: Coating thickness 20-50 μm±5 μm, adhesion ≥3B (ASTM D3359) Process Specifications: Spray pressure 0.3-0.6 MPa, cure 80-120℃×30 min
-
Sand blastingDescription: Abrasive jet finish for uniform matte texture. Process Compatibility: Post-machining blasting Materials: Metals, glass, stone Key Use: Architectural facades, engine blocks. Process Tolerance: Ra 1.6-6.3 μm, coverage ≥95% Process Specifications: Grit size 80-120, air pressure 0.4-0.7 MPa
Start Your
CNC Machining Project
CNC Machining Project
Upload a CAD file to receive instantly quotes, lead time, and DFM details for your CNC components. Specializing in CNC machining for metals and plastics, we provide adaptive production and shipping solutions to align with your product development needs.
What is Wire EDM?How Does Wire EDM Work?
Wire EDM (Wire Electrical Discharge Machining) is a precision machining process that uses a thin, electrically charged wire to cut conductive materials with extreme accuracy. By generating controlled electrical sparks (discharges) between the wire and the workpiece, it erodes material to create complex shapes, sharp corners, and fine details without physical contact. Ideal for hard metals like titanium, tool steel, and carbides, it is widely used in mold-making, aerospace, and medical device manufacturing.
Workpiece Setup:The conductive material is submerged in a dielectric fluid (usually deionized water) to cool the process and flush away debris.The wire (typically brass or copper) is threaded through the workpiece and connected to a power source.
Spark Generation:A voltage difference between the wire and workpiece creates repeated electrical discharges, melting and vaporizing tiny portions of the material.The dielectric fluid cools the area and removes eroded particles.
Precision Cutting:The wire moves along a programmed CNC path, guided by computer-controlled axes (X-Y-U-V), to achieve intricate geometries.Wire tension and feed rate are optimized to maintain cutting accuracy and surface finish.
Finishing:Multiple passes (roughing and finishing) may be used to achieve tight tolerances (±0.005 mm) and smooth surfaces (Ra < 0.2 µm).
-
CNC MachiningWe specialize in manufacturing custom prototypes and end-use parts with precise and complex designs through CNC milling,CNC turning, and CNC precision machining. -
Sheet Metal FabricationWe expert in the flexible manufacture of sheet metal prototypes and precision parts through laser cutting, stamping, metal bending, metal welding, riveting, embossing, flanging and tapping, chamfering and other processes. -
Injection Molding ServicesWorldsoaring provides plastic injection molding, rapid and production tooling, overmolding, and insert molding service. No MOQ required, all while maintaining high-quality and precision molding products. -
More ServicesSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price. -
SolutionsSLA, HP MJF, SLS, SLM technologies for functional prototyping and low-volume production. We manufacture 3d printed parts at competitive price.
Success Stories of Wire EDM Projects
FAQs
What materials can wire EDM cut?
Wire EDM processes all conductive materials including hardened steels (HRC 60+), superalloys (Inconel, Hastelloy), refractory metals (tungsten,
molybdenum), and conductive ceramics. Unlike conventional machining, it excels with heat-resistant (up to 1200°C) and ultra-hard (50-70 HRC)
materials critical for aerospace components, medical implants, and precision dies. Specialized techniques can machine semi-conductive materials
like PCD.
What is the difference between laser and wire EDM?
Laser cutting outperforms wire EDM in speed (3-5x faster for materials under 6.35mm thickness) due to non-contact thermal processing. However,
wire EDM provides superior accuracy (±0.002mm vs. ±0.1mm for lasers) and better edge finishes (Ra 0.2-0.8μm) without heat-affected zones,
making it ideal for hardened tool steels and precision tooling.
Why is wire EDM so accurate?
Wire EDM achieves micron-level precision through three key factors: 1) Ultra-fine brass/copper wires (0.1-0.3mm diameter) enable intricate cuts with
minimal kerf loss. 2) Advanced CNC systems control wire positioning within ±0.005mm tolerance. 3) Deionized dielectric fluid maintains optimal spark
gap consistency while removing microscopic debris. This combination delivers repeatable accuracy to ±0.002mm for complex geometries.
