Prototype to Low Volume Production Wire EDM Parts
F&M Tool and Die has 4 wire EDM and 2 EDM sinker machines ready to manufacture your prototype to low-volume custom manufactured EDM parts. We quote jobs in under 48 hours and deliver parts in 2-5 weeks, expedites welcome. Our sweet spot for EDM parts are in the 1-250 quantity range. Common EDM material used include Bronze, Copper, Tungsten, Carbon Steel, Stainless Steel, and more!
If you need intricate custom parts made from hard materials we are here for you!
CUSTOM WIRE EDM PARTS
- Lead Time – Parts in 2-5 Weeks
- Quoting – Quotes Returned Within 48 Hours
- Volume – Quantities 1-250+
- Part Size – Ranging from 1 in. x 1 in. x 1 in. to 35 in. x 26 in. x 15.5 in.
Wire Electrical Discharge Machining (Wire EDM) is a precision machining process that uses electrical discharges (sparks) to shape and cut conductive materials. It is particularly useful for creating intricate and complex shapes with tight tolerances. Wire EDM is commonly used in manufacturing industries such as aerospace, automotive, medical, and tool and die making.
Here’s a basic overview of how Wire EDM works:
- Setup:
- A workpiece, typically made of a conductive material such as metal, is set up in the machine.
- A thin wire electrode, often made of brass or tungsten, is threaded through the workpiece.
- Dielectric Fluid:
- The workpiece and the wire electrode are submerged in a dielectric fluid (usually deionized water). The dielectric fluid serves multiple purposes, including flushing away debris and conducting electricity.
- Electrical Discharge:
- A voltage difference is applied between the wire electrode and the workpiece. When the voltage reaches a critical point, an electrical discharge (spark) occurs between the wire and the workpiece, removing material from the workpiece.
- Material Removal:
- The sparks create micro-craters on the workpiece, and as the wire continuously moves, the material is eroded, resulting in the desired shape.
- Controlled Movements:
- The wire electrode is controlled by CNC (Computer Numerical Control) to precisely follow the programmed toolpath and create the desired shape.
- Finishing and Accuracy:
- Wire EDM is known for its ability to achieve high precision and tight tolerances. The process leaves a fine finish on the machined surfaces, often eliminating the need for additional finishing operations.
Wire EDM is particularly well-suited for cutting intricate and complex shapes, thin sections, and hard materials that are challenging to machine using traditional methods. It is often used in the production of tooling, dies, molds, and components for various industries. The process is non-contact, meaning there is no direct tool-to-workpiece contact, which makes it suitable for delicate or fragile materials.
Wire EDM Advantages
Wire Electrical Discharge Machining (Wire EDM) offers several advantages, making it a preferred method for certain applications in the manufacturing industry. Here are some of the key advantages:
- Precision and Accuracy:
- Wire EDM is known for its exceptional precision and accuracy. It can produce complex and intricate shapes with tight tolerances, making it suitable for applications where high precision is essential.
- Versatility:
- Wire EDM can be used to machine a wide range of materials, including conductive and hard materials such as metals, alloys, and exotic materials. It is particularly effective for cutting materials that are difficult to machine using traditional methods.
- No Tool Wear:
- Since the cutting tool is a wire electrode and there is no physical contact with the workpiece, there is minimal tool wear. This allows for consistent machining accuracy over time without the need for frequent tool changes.
- Thin Sections and Delicate Materials:
- Wire EDM is well-suited for machining thin sections and delicate materials that may be easily damaged by traditional cutting methods. The non-contact nature of the process is advantageous for working with fragile or intricate components.
- Complex Geometries:
- The process excels at machining complex and intricate shapes that may be challenging or impossible to achieve with conventional machining methods. It allows for the production of intricate dies, molds, and components.
- Fine Surface Finish:
- Wire EDM produces fine surface finishes on machined parts, often eliminating the need for additional finishing operations. This is beneficial for applications where a smooth surface is critical.
- Efficiency for Small Production Runs:
- While Wire EDM is often used for prototyping and the production of tooling and molds, it is also efficient for small to medium production runs. It offers flexibility in producing multiple parts without the need for extensive tool changes.
- Minimal Force on Workpiece:
- The process imposes minimal mechanical force on the workpiece, reducing the risk of distortion or stress. This is particularly advantageous for delicate or thin-walled components.
Despite its advantages, it’s worth noting that Wire EDM may not be the most efficient process for every application. Factors such as material type, part geometry, and production volume should be considered when selecting a machining method.
