Wire EDM Machining Services
Yonglihao Machinery specializes in Wire EDM Machining Services. Our customers widely recognize us for our unmatched precision. Our services are vital to producing complex parts for industries such as aerospace, medical, and automotive. Many buyers also compare Wire EDM against custom laser cutting services when evaluating 2D profile parts. All parts are certified to high-quality standards. They are certified through ISO 9001 and AS9100. This ensures reliability and excellence on every customer project.
- Typical tolerance: ±0.0002 in (feature-dependent)
- Up to: ±0.0001 in on qualified geometries after DFM/capability review
- Works on: tool steel, stainless, titanium, aluminum, carbide, nickel alloys
Why Choose Yonglihao for Wire EDM?
Precision You Can Specify
We focus on feature-level accuracy. This applies to complex profiles and tight internal corners. Our typical tolerance is ±0.0002 in. We can reach ±0.0001 in on qualified geometries. This follows a DFM review. Skim-cut strategies improve stability. They also ensure surface integrity on critical features.
Consistency for Repeat Builds
Our Wire EDM process uses controlled setups. We also rely on documented parameters. This supports repeat orders. You get a predictable fit and performance every time. It also reduces variation on hard materials. Traditional tools often drift due to wear. Our process avoids this.
Quality System
Our quality system holds ISO 9001 and AS9100 certifications. Inspection plans follow your drawings. We also match your acceptance criteria. We provide reports when required. We support traceability needs too. This includes revision control and material documents upon request.
What Is Wire EDM (WEDM)?
Wire EDM, or Wire Cut EDM, removes material using controlled electrical sparks. A thin wire acts as the electrode. The workpiece must be electrically conductive.
Cutting takes place in a dielectric bath, usually deionized water. The fluid cools the cutting zone and flushes away debris. It also stabilizes the sparks for a cleaner, more controlled cut.
When Wire EDM is the right choice
- Tight internal corners and complex contours
- Hardened steels, carbide, and high-strength alloys
- Thin-walled parts that deform under milling forces
- Precision inserts, dies, gauges, and fixture components
How wire EDM works
Wire Cut Electrical Discharge Machining (EDM) is a precise and complex process. It is used to make parts from conductive materials. This technology is essential for making fine and precise parts. They are vital to industries needing precision engineering, such as aerospace, medical, and automotive. The process is non-contact. It uses dielectric fluids. They ensure that even complex and delicate parts can be machined with little risk of damage, especially when compared with some laser cut services for tight internal corners.
- DFM + drawing review: We review your material, thickness, and datum strategy. We also check critical features. We then confirm the achievable tolerance and surface needs.
- Programming (CAD/CAM): We create toolpaths and define the cutting strategy. This includes rough cuts and skim cuts. If your geometry comes from laser design services, DXF/STEP files help confirm profiles, datums, and cut intent.
- Workholding & alignment: We clamp and align the workpiece to stable datums. This improves repeatability and inspection consistency.
- Wire threading & start hole: Internal profiles usually need a start hole. We can recommend a start-hole size based on the wire and path.
- Rough cut: Rough cutting removes most material efficiently. It sets the base for finishing passes.
- Skim cuts (finishing passes): Skim cuts improve surface finish and dimensional stability. They also reduce the recast layer for critical features.
- Inspection + reporting: We inspect key dimensions per your drawing. Reports are available upon request.
Wire EDM Capabilities
Our Wire EDM capabilities focus on stable accuracy and fine-feature control. Final results depend on several factors. These include material, thickness, geometry, flushing, and finishing strategy.
Description | Capability |
|---|---|
Maximum Part Size | Up to 400 × 300 × 200 mm (15.7 × 11.8 × 7.9 in.). This is a typical shop baseline. Larger parts are available upon review. |
Minimum Part Size | Recommended ≥ 3 × material thickness. A practical minimum is 2 mm (0.08 in.), depending on workholding. |
General Tolerances | Typical: ±0.005 mm (±0.0002 in.) on qualified features. Best-case: ±0.0025 mm (±0.0001 in.) after review and finishing passes. |
Maximum Material Thickness | Carbon/Tool steel: up to 200 mm (7.9 in.) typical. Thicker parts are upon review. Stainless/Titanium/Carbide: capability depends on grade and finish. |
Kerf (Cut Width) | Approximately wire diameter plus spark gap. Typical kerf is 0.12–0.35 mm (0.005–0.014 in.) depending on settings. |
Minimum Inside Corner Radius | Approx. wire radius plus gap: 0.06–0.20 mm (0.002–0.008 in.) depending on wire diameter. |
Edge Condition | Fine EDM striations are normal. Skim cuts reduce surface roughness and recast layer. |
Wire Types | Brass wire and coated brass wire. Typical wire diameters are 0.10–0.30 mm (0.004–0.012 in.). Finer wire is available upon review. |
Dielectric Fluid | Deionized water is typical for Wire EDM. |
Repeatability (Reference) | Typically ±0.003 mm (±0.00012 in.) for stable setups. It may vary with thickness and flushing conditions. |
Positioning Accuracy | Typically ±0.005 mm (±0.0002 in.) for machine reference. Actual part accuracy depends on cutting strategy and thermal stability. |
Lead Time | 5–7 business days is typical for standard complexity. Expedited options are available upon review. |
Capability note: Unless specified on the drawing, we follow customer-defined criteria for inspection and acceptance. The figures above are typical baselines. We confirm them during DFM review.
Materials We Can Machine
Wire EDM works on electrically conductive materials. Common materials we cut include:
- Tool steels & hardened steels: D2, H13, A2, S7, SKD11, SKD61 for molds, dies, and wear parts.
- Stainless steels: 304, 316, 17-4PH, 420, 440C for corrosion resistance and strength.
- Titanium alloys: Ti-6Al-4V and related grades for aerospace and medical parts.
- Aluminum alloys: 6061, 7075, and other conductive grades. Edge quality depends on thickness and finishing.
- Cemented carbide: Tungsten carbide and carbide wear parts. Wire EDM helps preserve precision on hard materials.
- Nickel-based alloys: Inconel 625/718 and other high-temperature alloys.
- Copper alloys: Copper, brass, and bronze for conductive parts and fixtures.
Not suitable: plastics, ceramics, glass, and other non-conductive materials.
CNC Machining Surface Finishes
In addition to our expert CNC machining services, Yonglihao Machinery also offers a variety of surface finishing options to meet both your cosmetic and functional requirements.
Parts are delivered right after Wire EDM cutting. The surface shows EDM striations, not tool marks. This is best when appearance is not critical. It also works if you plan to apply a secondary finish.
We use extra finishing passes, or skim cuts, for a better finish. These improve surface quality and dimensional stability on key features. This is recommended for precision tooling and medical parts. It is also good for thin or fragile geometries.
Polishing is a separate step after EDM. It is suitable for decorative surfaces. It is also for parts needing a smoother feel. Masking may be needed to protect critical dimensions and sharp features.
This creates a uniform matte look. It also helps remove light surface discoloration. We recommend it mainly for cosmetic surfaces. It is not advised for tight-fit or sealing areas unless approved.
Hard anodizing after blasting/polishing to increase wear resistance and durability. Ideal for aluminum parts needing higher surface hardness. Hard coat thickness impacts part dimensions; specify tolerance zones and masking.
This provides a stronger matte texture. It also cleans external surfaces. It may slightly round edges and affect fine details. This is best for non-critical cosmetic areas.
A chemical conversion finish for carbon/tool steels to improve appearance and provide light corrosion resistance (often with oil). Stainless options are available upon review, as processes and results differ by grade.
A durable paint-like coating for cosmetic protection and general wear resistance. Best for brackets, covers, fixtures, and non-precision surfaces. Not recommended for tight fits, fine features, or sealing surfaces due to coating thickness.
Adds a protective conversion layer to improve corrosion resistance while maintaining good electrical conductivity. Common for aerospace, electronics, and functional aluminum parts.
Improves corrosion resistance, wear resistance, conductivity, or appearance depending on plating type. Plating thickness and masking must be defined for precision features. For high-strength steels, hydrogen embrittlement relief may be required.
Adds directional texture for a “metallic” look. Suitable for flat or accessible external faces. Not recommended for internal fine features or precision fits.
Smooths parts using abrasives to remove burrs and sharp edges. Works best for small parts with non-critical edges. May round sharp corners and is not recommended for precision edge geometry
Advantages of Wire EDM Machining
Wire EDM machining is ideal for precision manufacturing. This is because of its high accuracy and ability to handle complex shapes. It is also good for hard materials and creates minimal stress. In some projects, custom laser cutting is chosen for speed on thin sheet profiles, while Wire EDM is selected for tighter internal detail.
High Precision and Accuracy: Wire EDM machining has very tight tolerances. They are often down to +/- 0.0002 inches. These tight tolerances ensure the high-quality parts that the aerospace, medical, and automotive industries need.
Ability to cut complex shapes: EDM wire can follow complex paths. It creates fine shapes and sharp corners. They are hard to make with traditional methods.
Suitable for hard materials: It can effectively cut hard materials such as hardened steel, titanium, and carbide. The machining process involves no physical contact. This stops tool wear and ensures steady performance.
Minimal mechanical stress on the workpiece: The process is non-contact. It minimizes stress. This stops fragile or thin workpieces from deforming or breaking. This stress-free cutting maintains material integrity and ensures accuracy.
FAQ
Typical tolerance is about ±0.0002 in. Up to ±0.0001 in is possible after a capability review. Thickness, geometry, and flushing conditions affect the final result.
The finish depends on the material and skim-cut strategy. More finishing passes improve surface quality. Tell us your target Ra if you have one.
We can machine any electrically conductive material. This includes steel, titanium, aluminum, carbide, nickel alloys, and copper alloys.
No. Wire EDM requires an electrically conductive material.
Yes, for most internal profiles. We can recommend a start-hole size and location. This depends on the wire and cutting path.
Wire EDM is great for sharp internal corners and hard materials. It creates tight tolerances with minimal stress. Laser cutting is faster for some profiles, and a laser cutting service can be efficient for sheet parts, but it can add heat effects. It also has limits on precision details. For sourcing, you may see terms like laser cutting services, laser cutter service, lasercutting service, or laser cut services used interchangeably.
