Best Machining
Wire EDM Machining Services
- 🎯±0.0001″ Tolerances
- 🏆ISO 9001 & AS9100 Certified
- ⚡24/7 Quote Response
Trusted by Industry Leaders: 1,000+ Companies Choose Our Precision Wire EDM Services
Core Advantages of Our Wire EDM Services
Unrivaled Precision
Achieve tolerances as tight as ±0.0001″ with our state-of-the-art equipment and expert machinists, ensuring your parts meet the most demanding specifications.
Complex Geometries
Cut intricate shapes, sharp internal corners, and complex profiles that traditional machining cannot achieve, with no tool wear or workpiece distortion.
Hard Material Capability
Machine any conductive material regardless of hardness, including pre-hardened tool steels, carbides, and exotic superalloys.
Certified Quality
ISO 9001, AS9100D, ISO 13485, and IATF 16949 certified processes ensure the highest standards of quality and traceability.
Superior Surface Finish
Achieve exceptional surface finishes down to 16 μin Ra without secondary operations, reducing costs and lead times.
Stress-Free Machining
Non-contact cutting process eliminates mechanical stresses, preventing part distortion and maintaining dimensional accuracy.
What is Wire EDM?
Think of wire EDM like a wire cutting through cheese, but instead of physical pressure, it uses thousands of tiny electrical sparks per second to “melt” its way through even the hardest metals. The wire never actually touches the material, making it perfect for delicate or complex parts.
Key Technical Parameters:
- Operating Voltage:50-300V
- Wire Diameter:0.001″-0.012″
- Achievable Tolerance:±0.0001″
- Surface Finish Range:4-250 μin Ra
Advanced Wire EDM Machining Technology & Precision Process Capabilities
🔥 Wire EDM Process
Non-contact cutting: Electrical sparks erode material without physical contact, eliminating cutting forces and tool wear. Perfect for delicate features and hard materials.
- Thousands of sparks per second
- Precise material removal
- No mechanical stress
- Consistent quality
🔧 Traditional Machining
Contact cutting: Physical tools cut material through mechanical force, causing tool wear and potential workpiece distortion. Limited by tool access and material hardness.
- Tool wear and replacement
- Cutting force limitations
- Hardness restrictions
- Geometric constraints
Wire EDM Limitations & Considerations
Wire EDM Limitations
- Slower Material Removal：Much slower material removal rate than CNC milling. Tight tolerances and fine surface finishes require slow repeat passes, increasing machining time significantly.
- Conductivity Requirement：Only electrically conductive materials can be machined. Ceramics, plastics, and composites cannot be processed unless they have conductive properties.
- Higher Operating Cost：Slow machining speeds and expensive consumables (wire, filters, deionized water) can result in higher per-part costs compared to conventional machining.
- Through-Cut Requirement：Cannot be used for blind features and cavities. The wire must pass completely through the part from top to bottom guide, limiting design possibilities.
Wire EDM Design Considerations
- Material Conductivity
Material must be electrically conductive. Test with multimeter if uncertain about conductivity.
- Kerf Width
Kerf width typically ranges from 0.001″ to 0.012″ depending on wire diameter and cutting parameters.
- Surface Finish
Typical surface finish ranges between 16 and 64 microinches. Finer finishes require slower cutting speeds.
- Edge Quality
Edges will be smooth but have a characteristic matte appearance due to the spark erosion process.
Comprehensive Wire EDM Material Capabilities & Machining Expertise
Hardness Range:45-65 HRC.
Common Grades:
- D2: High-carbon, high-chromium cold work steel
- A2: Air-hardening tool steel with excellent toughness
- H13: Hot work steel for high-temperature applications
- S7: Shock-resistant tool steel for impact applications
- O1: Oil-hardening tool steel for precision tooling
- M2: High-speed steel for cutting tools
Typical Applications:
- Progressive die components
- Injection mold inserts
- Stamping punches and dies
- Cutting tool profiles
- Precision gauges and fixtures
Wire EDM Advantages:
Machines pre-hardened steels without annealing, eliminates heat treatment distortion, achieves complex geometries impossible with conventional machining, maintains sharp corners and fine details.
Hardness Range:28-45 HRC
Common Grades:
- 304: General purpose austenitic stainless
- 316/316L: Marine-grade with superior corrosion resistance
- 17-4 PH: Precipitation hardening martensitic steel
- 15-5 PH: High-strength precipitation hardening
- Custom 450: Ultra-high strength stainless
- Nitronic 60: Galling-resistant stainless
Typical Applications:
- Surgical instrument components
- Medical device housings
- Food processing equipment
- Chemical processing parts
- Marine hardware components
Wire EDM Advantages:
Eliminates work hardening issues, maintains corrosion resistance, achieves biocompatible surface finishes, prevents galling during machining, enables thin-wall features without distortion.
Hardness Range:35-50 HRC
Common Grades:
- Inconel 718: Nickel-chromium superalloy
- Inconel 625: High-temperature oxidation resistance
- Hastelloy X: Excellent high-temperature strength
- Waspaloy: Turbine blade applications
- René 41: Gas turbine engine components
- Haynes 230: Ultra-high temperature applications
Typical Applications:
- Turbine blade cooling slots
- Combustor liner features
- Heat exchanger components
- Rocket engine parts
- Nuclear reactor components
Wire EDM Advantages:
Overcomes extreme work hardening tendencies, eliminates tool wear from abrasive materials, maintains metallurgical properties, achieves intricate cooling passages, enables stress-free machining.
Hardness Range:85-95 HRA
Common Grades:
- WC-Co: Tungsten carbide with cobalt binder
- WC-Ni: Nickel-bonded tungsten carbide
- TiC: Titanium carbide for wear resistance
- TaC: Tantalum carbide ultra-hard grade
- Cermet: Ceramic-metal composite materials
- PCD: Polycrystalline diamond composites
Typical Applications:
- Cutting tool inserts
- Wear-resistant components
- Drawing dies and punches
- Nozzles and orifices
- Precision gauges
Wire EDM Advantages:
Only practical method for machining ultra-hard materials, eliminates grinding wheel loading, achieves complex profiles impossible by grinding, maintains edge sharpness, prevents thermal damage.
Grades: Ti-6Al-4V, Ti-6Al-2Sn-4Zr-2Mo, CP Titanium
Hardness: 30-45 HRC
Aerospace and medical applications requiring high strength-to-weight ratio, corrosion resistance, and biocompatibility. Wire EDM eliminates work hardening and galling issues common with conventional machining.
Hardness: 15-40 HRC
Electrical and electronic applications requiring excellent conductivity and thermal properties. Wire EDM provides superior surface finish and dimensional accuracy for precision electrical components.
Hardness: Variable
Specialized applications in nuclear, aerospace, and research industries. Wire EDM is often the only practical machining method for these extremely difficult-to-machine materials.
Expert Wire EDM Material Selection Guidance
Material Testing
Eliminate material-related machining failures through comprehensive pre-processing evaluation. Our testing protocols verify electrical conductivity, assess machinability characteristics, and analyze alloy composition impacts on EDM performance. Detailed material characterization reports ensure successful project outcomes while optimizing cutting parameters for maximum efficiency and superior surface finish quality.
Parameter Optimization
Proprietary cutting parameter database covering 200+ material grades ensures optimal EDM performance for every application. Custom-developed parameters maximize cutting speed while maintaining precision tolerances and surface finish requirements. Expert optimization reduces machining time, minimizes wire consumption, and delivers consistent quality across prototype, low-volume, and production manufacturing scenarios.
Quality Assurance
Industry-leading quality assurance provides complete material and process certification meeting AS9100D, ISO 13485, and IATF 16949 standards. Comprehensive documentation includes Mill Test Certificates, material traceability records, compliance certifications, and third-party verification. Full chain of custody documentation ensures complete accountability from raw material through finished part delivery.
Wire EDM Surface Finishes & Post-Processing Options
Internal Components: Parts where surface texture doesn’t affect functionality
Tooling Components: Stamping dies, forming tools where EDM texture aids material flow
Non-Critical Surfaces: Areas not requiring specific surface finish specifications
Cost-Sensitive Projects: Applications prioritizing dimensional accuracy over surface aesthetics
Medical Surgical Instruments: Biocompatible surfaces with complete recast layer removal
Optical Components: Reflective surfaces requiring minimal light scattering
Precision Gauges: Measurement surfaces requiring smooth contact
Aerospace Sealing Surfaces: Critical interfaces requiring leak-tight performance
Pre-Coating Preparation: Optimal surface for powder coating, anodizing, or plating adhesion
Aesthetic Finishes: Uniform matte appearance for consumer products
Recast Layer Removal: Applications requiring complete elimination of EDM surface effects
Deburring: Removal of sharp edges and micro-burrs from EDM cutting
Pharmaceutical Equipment: Smooth, cleanable surfaces for sterile processing
Food Processing Components: Sanitary surfaces resistant to bacterial adhesion
Corrosive Environments: Enhanced corrosion protection for chemical processing equipment
Semiconductor Tooling: Ultra-clean surfaces for contamination-sensitive applications
Hydraulic Manifolds: Corrosion protection and wear resistance for fluid power systems
Electronics Housings: EMI shielding and corrosion protection with aesthetic appeal
Wear Surfaces: Type III hard anodizing for sliding contacts and high-friction applications
Medical Devices: Biocompatible, corrosion-resistant surfaces for surgical instruments
Outdoor Components: UV-stable, weather-resistant finish for architectural and automotive applications
Consumer Products: Aesthetic appeal with excellent durability for appliances and electronics
Corrosion Protection: Long-term protection for steel components in harsh environments
Custom Colors: Brand-specific colors and finishes for OEM applications
Hydraulic Components: Chrome plating for cylinder rods, pistons, and valve bodies
Electronic Components: Nickel plating for solderability and EMI shielding
Automotive Parts: Decorative chrome and corrosion-resistant zinc plating
Fasteners & Hardware: Zinc plating with chromate for cost-effective corrosion protection
Wire EDM Machining Capabilities: Process Performance Comparison Matrix
This comprehensive performance matrix compares Wire EDM electrical discharge machining against conventional manufacturing processes including CNC milling, laser cutting, waterjet cutting, and plasma cutting across ten critical performance criteria. Detailed analysis covers dimensional precision (±0.0001″ Wire EDM capability vs. ±0.0005″ CNC milling), surface finish quality (4-250 μin Ra range), hard material processing capability (up to 95 HRA tungsten carbide), complex geometry freedom, material thickness limitations, cutting speed efficiency, operating costs, and setup complexity. The matrix provides objective performance ratings enabling informed manufacturing process selection based on specific application requirements, material properties, and quality standards.
| Capability | Wire EDM | CNC Milling | Laser Cutting | Waterjet | Plasma Cutting |
|---|---|---|---|---|---|
| Dimensional Tolerance | ±0.0001″ (±2.5μm) | ±0.0005″ (±13μm) | ±0.003″ (±76μm) | ±0.003″ (±76μm) | ±0.020″ (±500μm) |
| Surface Finish (Ra) | 4-250 μin (0.1-6.3μm) | 16-125 μin (0.4-3.2μm) | 125-500 μin (3.2-12.7μm) | 125-250 μin (3.2-6.3μm) | 500-2000 μin (12.7-50μm) |
| Hard Material Capability | Any hardness (conductive) | Limited (< 45 HRC) | Good (< 60 HRC) | Excellent (any hardness) | Fair (< 50 HRC) |
| Sharp Internal Corners | Perfect (0.001″ radius) | Limited by tool radius | Excellent | Good | Fair |
| Material Removal Rate | Very Low | Very High | High | Medium | Very High |
| Tool Wear | None (continuous wire) | Significant | None | None | None |
| Heat Affected Zone | Minimal (0.0001-0.0005″) | None | Moderate (0.001-0.005″) | None | Significant (0.010-0.050″) |
| Thin Wall Capability | Excellent (no distortion) | Poor (vibration) | Good | Good | Fair |
| 3D Complexity | Limited (2.5D + taper) | Excellent (full 3D) | 2D only | 2D only | 2D only |
| Operating Cost | Medium-High | Low-Medium | Low-Medium | Medium | Low |
Design Assistance for Wire EDM Parts
Our engineers review your Wire EDM designs to optimize manufacturability, reduce costs, and improve quality for precision components in tool steels, stainless steels, superalloys, and carbides. We provide expert guidance on tolerances, geometries, and material selection to ensure your parts leverage the full capabilities of Wire EDM technology while avoiding common design pitfalls.
We Supply Precision Wire EDM Parts to Clients Across These Industries
Advanced Wire EDM Technology
Flexible Production Capacity
Strict Quality Assurance
Why Choose Us
50% to 100% lower than Europe and America
ISO9001:2015 certified and committed to continuous improvement
Your Parts Delivery in as fast as 3 days
From inquiries to issues, our team provides you 24/7 instant support
From metals to plastics, meets your every requirement for precision and quality
Plating, anodizing, heat treating, powder coating, and other finishing processes,tailored to your needs
Speed up your product development with quick, accurate prototypes
15 years serving European and American clients, tolerances down to +/- 0.001
Every part is carefully wrapped and secured, preventing any potential damage during transportation
How We Ensure Accurate, On-Time Wire EDM Machine Parts Delivery
To ensure your order is processed accurately and delivered on time, your part design is thoroughly reviewed before production begins. All specifications, including materials and surface finish, are carefully checked to prevent any issues. Throughout manufacturing, in-process inspections are performed to maintain consistent quality and precision. After production, a final inspection is conducted, and your parts are carefully packaged to ensure safe delivery. With this rigorous process, your parts are guaranteed to meet high-quality standards and be delivered on time, providing you with peace of mind.
Your part design will be reviewed by our engineering team, including 3D/2D drawings, material, surface finish, and structure. Any necessary adjustments or optimizations will be communicated promptly to address potential issues before production begins.
You will receive parts made from the highest quality raw materials, carefully selected to meet your exact specifications. Certification reports with material details, grades, and properties are available upon request, ensuring transparency and confidence in your order.
Your parts are manufactured using advanced CNC Turning, Milling, and Grinding equipment, ensuring precision and accuracy. With in-house machinery and high-precision testing tools, we guarantee top-quality results for even the most complex designs.
First article and in-process inspections are conducted to ensure your parts meet design and quality standards. Continuous monitoring during production ensures precision and compliance with your specifications, guaranteeing high-quality results.
Before shipment, all your parts are inspected for critical dimensions, tolerances and appearance. Then they are carefully packaged to prevent damage during transit, and inspection reports are provided upon request, ensuring your parts meet your standards.
Precision Without Compromise: Our Wire EDM Quality Promise
Client Testimonial
SEE WHAT OUR CUSTOMERS SAY ABOUT US?
Real Feedback, Real Results: Hear directly from our clients about the exceptional quality and service we provide with every project we deliver.
Frequently Asked Questions
Get answers to common questions about our wire EDM machining services
Wire EDM (Electrical Discharge Machining) is a precision manufacturing process that uses an electrically charged wire to cut conductive materials. The wire acts as an electrode, creating controlled electrical sparks that erode material with extreme accuracy. This non-contact process can achieve tolerances as tight as ±0.0001″ and is ideal for complex geometries that traditional machining cannot produce.
Wire EDM can routinely achieve tolerances of ±0.0001″ (±0.0025mm) and can reach ±0.00004″ (±0.001mm) for specialized applications. Tolerance capability depends on part geometry, material type, thickness, and specific machine capabilities. Our precision machines and expert programming ensure consistent results within your specified tolerances.
Wire EDM can cut any electrically conductive material including tool steels, stainless steels, titanium alloys, superalloys like Inconel, tungsten carbide, and exotic materials regardless of hardness. It’s particularly effective for pre-hardened materials that are difficult to machine with traditional methods. The material must be electrically conductive for the EDM process to work.
Lead times vary based on complexity, quantity, and current workload. Simple prototypes can be completed in 3-5 days, while complex projects may take 2-4 weeks. Production runs typically require 1-3 weeks depending on volume. We work closely with you to meet your specific deadlines and can expedite urgent projects when needed.
We accept all major CAD formats including STEP, STP, SLDPRT, STL, DXF, IPT, 3MF, IGES, and more. Our online quote system makes it easy to upload files and receive detailed quotes within 24 hours. PDF drawings are also acceptable for initial quotes, though 3D CAD files are preferred for accurate pricing.
Our large-format machines accommodate workpieces up to 29.5″ × 19.6″ × 15.7″ with a maximum weight of 4,400 lbs. We also have smaller precision machines for micro-machining applications. For larger projects, we can section parts and provide assembly services, or recommend alternative manufacturing approaches.
Yes, we offer comprehensive finishing services including deburring, surface treatments, heat treating, anodizing, plating, and protective coatings. Our goal is to deliver finished parts ready for your application, reducing your supply chain complexity and ensuring consistent quality throughout the process.
We have no minimum order quantity. Whether you need a single prototype or thousands of production parts, we can accommodate your needs with competitive pricing.
We maintain ISO 9001:2015 for quality management, AS9100D for aerospace applications, ISO 13485 for medical devices, and IATF 16949 for automotive manufacturing. We’re also ITAR registered for defense applications. All certifications are regularly audited and maintained to ensure compliance with the most stringent industry standards.
Still have questions? Our engineering team is here to help.
How Wire EDM Works
Related Manufacturing Services
Advanced CNC machining capabilities deliver precision milling and turning services for complex aerospace, medical, and automotive components. Our state-of-the-art equipment processes materials including aluminum, stainless steel, titanium, and engineering plastics with tolerances to ±0.0005". Complete inspection, material certifications, and engineering support ensure first-time-right quality for demanding applications.
High-precision CNC turning services for cylindrical parts, shafts, bushings, and threaded components. Swiss-type and conventional CNC lathes handle diameters from 0.125" to 12" with ±0.0005" tolerances and 16-32 μin Ra surface finishes. Process aluminum, brass, stainless steel, and engineering plastics. Fast prototyping (3-5 days) and production volumes with complete quality documentation.
Advanced CNC milling services with 3-axis, 4-axis, and 5-axis capabilities for complex geometries, pockets, and contoured surfaces. Achieve ±0.0005" tolerances, 16-63 μin Ra finishes, and machine aluminum, steel, titanium, and plastics. Vertical and horizontal machining centers handle parts up to 40" x 20" x 20". Engineering support and rapid prototyping available.
Ready to Start Your CNC Turning Project?
Get high-quality custom parts with fast turnaround times and competitive pricing.