Electrical Discharge Machining (EDM) – Sink EDM and Wire EDM
EDM is a non-cutting manufacturing process used for machining electrically conductive materials. There are two main methods: Sink EDM and Wire EDM – both of which we use to create components when traditional machining techniques reach their technical limits.
For us, EDM is not a theoretical concept but a daily practice. We employ it strategically where geometries are intricate, materials are extremely hard, or tolerances are exceptionally tight. Whether for prototypes, single parts, or series production: we don’t use EDM “just for the sake of the technology” but always with a focus on functionality, fit, and cost-effectiveness for our customers.
How EDM Works at Our Facility
Unlike milling or turning, material removal in EDM is not achieved through mechanical forces, but through controlled electrical discharges. Sparks are generated between the tool (electrode or wire) and the workpiece, removing material in a localized manner. The workpiece is not mechanically stressed during the process – a significant advantage when machining sensitive contours or very hard steels.
We control the process using precisely defined parameters such as current strength, pulse duration, and flushing strategy. The dielectric fluid (the process liquid) performs several tasks: it cools, removes eroded particles, and stabilizes the spark process. The result: reproducible precision.
Sink EDM – When Depth of Shape and Detail Matter
In sink EDM, we create an electrode whose geometry is transferred onto the workpiece. This “negative mold” is then carefully inserted into the workpiece. This is where our strength lies: We consider the electrode and the workpiece as a unit. Only in this way can we produce parts that not only fit, but function reliably in the long term.
Typical tasks we solve using sink EDM:
- Deep cavities and undercuts
- Structured surfaces
- Functional pockets
- Sharp internal edges
- Inserts for toolmaking
Especially with complex shapes, experience makes the difference. We select materials, geometry, and EDM strategy to ensure shape accuracy and surface quality – no matter how deep or intricate the details are.
Wire EDM – Clean Contours, Reproducible Cuts
In wire EDM, a thin, charged wire acts as the tool. It cuts the workpiece without contact along a defined contour. This process is the first choice when:
- Profiles need to be exact
- Cutting gaps need to be minimal
- Burr-free edges are required
- Geometries are complex
In practice, we use wire EDM to manufacture items such as punches, dies, functional profiles, or mold plates. The advantage in series production becomes clear: each part is identical, with no compromises in quality.
When We Use EDM – and When We Choose Not To
EDM is not a “one-size-fits-all” tool. We use it when it is technically advantageous. Our strength lies in assessing honestly whether EDM offers the best added value or if another method would be more cost-effective.
Typical reasons we choose EDM:
- Very hard materials
- Smallest radii
- Tight tolerances
- Complex internal contours
- Stress-sensitive components
- High reproducibility requirements
Our advice begins by understanding your part – not when the machine starts.
Materials? It’s Our Everyday Business.
We perform EDM on all electrically conductive materials, such as:
- Tool steel
- Stainless steel
- Carbides
- Copper
- Aluminum
- Titanium
- Special alloys
It’s not about hardness, but conductivity. And our production is set up for just that.
What Sets Us Apart – Technology + Responsibility
Machines alone do not produce quality.
It is the combination of experience, process understanding, and honest advice.
What our customers value about us:
- Well-structured processes
- Dedicated points of contact
- Realistic timeline planning
- Clean documentation
- Consistent quality
- Solution-oriented thinking
We don’t see every part as just an “order,” but as a responsibility.
Quality Thinking in the Process – Not Just at the End
Quality is created during the machining process.
Our machines monitor:
- Spark stability
- Material removal behavior
- Position accuracy
- Repeatability
Measurements are not performed “at the end” but continuously during the process. This allows us to detect deviations early and prevent scrap, rather than simply documenting it after the fact.
Conductive Materials and Surface Quality
We process all electrically conductive materials – regardless of hardness or alloy composition. These include tool steels, stainless steel, copper, aluminum, titanium, and special alloys. Another significant advantage of our EDM technology lies in the excellent surface quality we can achieve. By precisely controlling EDM parameters such as pulse duration, current strength, and flushing, we can influence surface roughness values exactly and tailor them to the required application conditions. Upon request, we can achieve surface qualities down to fine micrometer levels – reliably and reproducibly.
Sinking EDM Machines
| Number | Cavity type EDM | X | Y | Z |
|---|---|---|---|---|
| 4 | Sinking EDM Machines: Charmilles | 600 | 400 | 350 |
Minimal Kerf Width with WEDM
In wire EDM (WEDM), we use extremely fine wire diameters, enabling an exceptionally narrow kerf width. This allows even the most delicate contours to be machined with minimal material removal. The reduced material removal not only ensures high dimensional accuracy but also supports cost-effective production by minimizing scrap. Especially for complex geometries and precise functional contours, our customers benefit from this technology through maximum repeatability and clean cut edges – without any mechanical stress on the workpiece.
WEDM Machines
| Number | WEDM Wire EDM | X | Y | Z |
|---|---|---|---|---|
| 1 | Wirecut EDM Machines: Charmilles | 350 | 300 | 250 |
In Short: Why Choose EDM with Us?
- Because we don’t just shape – we understand.
- Because precision is not just a buzzword for us.
- And because we prefer planning it right the first time, rather than correcting it twice.
