MetalworksPlus EDM machine cutting complex metal cavity with precision spark erosion
MetalworksPlus EDM workshop floor with advanced wire EDM and sinker EDM equipment
About the Process

What Is Electrical Discharge
Machining (EDM)? MW+

EDM is an advanced non-contact subtractive manufacturing process that removes material from electrically conductive workpieces through precisely controlled electrical spark discharges. Unlike conventional cutting, EDM exerts zero mechanical force — enabling machining of hardened steels, carbide, Inconel, and fragile geometries without distortion.

Controlled Spark Erosion at 8,000–12,000°C
Each electrical discharge creates a plasma channel exceeding the temperature of the sun's surface. Material vaporizes in microseconds within a precisely maintained 0.02–0.05mm dielectric gap, controlled by adaptive servo systems.
Dielectric Fluid System
Parts are submerged in deionized water or EDM oil which flushes eroded debris particles, cools the workpiece between discharges, and maintains precise dielectric breakdown conditions for repeatable material removal.
Adaptive CNC Servo Control — 200kHz Pulse Rate
Digital servo systems monitor gap voltage 50,000×/second, continuously adjusting electrode position and discharge parameters in real-time — maintaining tolerances to ±0.005mm with micron-level repeatability across production runs.
Hardness Is Never a Limitation
Tungsten carbide at 90 HRA, hardened D2 at 62 HRC, Inconel 718, titanium alloys — any electrically conductive material is processed with identical precision. EDM is the only practical method for many of these materials.
Our Workflow

The EDM Machining Process — Step by Step MW+

From CAD file upload to CMM-verified delivery — a transparent, quality-driven engineering workflow for every order.

01
DFM Engineering Review
Dedicated EDM engineers review your CAD file for feasibility, electrode design requirements, optimal cutting strategy, and tolerance achievability.
02
Electrode & Wire Setup
Graphite/copper electrodes manufactured in-house on our CNC milling center. Wire threaded, tensioned, and auto-calibrated on Sodick / Makino WEDM.
03
Rough EDM Cut
High-power rough cut rapidly removes bulk material at elevated pulse energy. Generates the near-net-shape geometry while preserving dimensional stock.
04
Precision Skim Passes
2–4 progressive skim cuts at reduced energy refine geometry, achieve final tight tolerance, and improve surface finish to Ra 0.2µm. Recast layer minimized.
05
CMM Verification & Report
Zeiss Contura CMM and Keyence vision systems verify all critical dimensions. Full dimensional inspection report and material certifications issued per order.
EDM Capabilities

Wire EDM · Sinker EDM · EDM Drilling MW+

Advanced Sodick AQ750L and Makino EDAF3 platforms with adaptive servo control, automated wire threading, real-time spark gap optimization, and integrated 5-axis CNC positioning.

Wire EDM (WEDM)

Wire Electrical Discharge Machining

A continuously-fed brass/copper wire (Ø0.02–0.30mm) serves as the cutting electrode, eroding through conductive workpieces via controlled spark discharges. Ideal for through-profiles, complex contours, punch-and-die sets, extrusion dies, and gears with sharp internal corners impossible to achieve by grinding.

±0.005mm
Tolerance
Ra 0.2µm
Surface Finish
±30°
Max Taper
Sinker EDM (Ram EDM)

Sinker / Die-Sinking EDM

A precisely shaped graphite or copper electrode descends into the workpiece in a controlled Z-axis servo motion, transferring its negative geometry to create blind cavities, pockets, 3D features, and textured surfaces. Essential for injection mold cavities, aerospace cooling channels, and medical tooling with undercuts or sharp-cornered features.

±0.008mm
Tolerance
Ra 0.4µm
Surface Finish
3D Cavities
Capability
EDM Drilling

Small Hole EDM Drilling

High-speed EDM drilling using rotating tubular electrodes with internal dielectric flushing creates precision small holes from Ø0.1mm with depth-to-diameter ratios exceeding 50:1 — impossible with mechanical drills. Critical for turbine blade film cooling holes, fuel injector nozzles, wire EDM start holes, and high-aspect-ratio micro-features in superalloys.

Ø0.1mm
Min Hole Size
50:1
Aspect Ratio
±0.01mm
Position Accuracy
By the Numbers

MetalworksPlus EDM — Technical Performance

±0.005mm
Wire EDM Precision Tolerance
Verified by Zeiss Contura CMM
Ra 0.2µm
Mirror Surface Finish
Multiple Precision Skim Passes
65 HRC
Maximum Material Hardness
No Limitation — Any Conductor
24/7
Production Capacity
3–5 Day Wire EDM Prototypes
Technical Specifications

EDM Tolerances & Metrology Standards

Industry-leading precision backed by traceable measurement systems — Zeiss Contura CMM, Keyence IM-7030 vision system, and Mitutoyo SJ-410 surface profilometer. First Article Inspection (FAIR) per AS9102 available.

EDM Process Standard Tolerance High-Precision Capability Surface Finish Ra Typical Applications
Wire EDM (WEDM)
Sodick AQ750L		 ±0.01mm ±0.005mm (0.0002") 0.2 – 0.8µm Extrusion dies, gears, splines, punch plates, electrical contacts, complex profiles
Sinker EDM (Ram)
Makino EDAF3		 ±0.015mm ±0.008mm 0.4 – 1.2µm Mold cavities, blind pockets, aerospace cooling channels, medical tooling
EDM Drilling
High-Speed		 ±0.02mm ±0.01mm 0.8 – 1.6µm Turbine blade cooling holes, fuel nozzles, wire start holes ≥ Ø0.1mm
GD&T — True Position
AS9102 FAIR		 ±0.01mm ±0.003mm — Flight-critical parts, medical devices, precision fixtures, alignment features

All dimensions verified by Zeiss Contura CMM with traceable calibration. Material certifications (MTR) and full traceability documentation provided on request. FAIR reports per AS9102 standard available for aerospace and defense programs.

EDM in Action

A look inside MetalworksPlus's precision EDM facility — where advanced Sodick and Makino machines deliver micron-level accuracy around the clock.

MetalworksPlus wire EDM machine cutting precision metal component — spark erosion in progress Wire EDM — Precision Spark Erosion
Close-up of EDM precision machined metal part showing mirror surface finish and tight tolerances Mirror EDM Surface Finish
MetalworksPlus EDM workshop with multiple precision EDM machines operating simultaneously EDM Workshop Floor
Material Expertise

Materials We Machine by EDM

Any electrically conductive material — from soft C110 copper to 90 HRA tungsten carbide — processed with equal precision. Material hardness is never a limitation with EDM.

🔩

Tool & Die Steels

D2A2O1S7H13M2P20

High wear resistance for punch dies, forging tools, and injection mold inserts. Typically machined post heat-treatment at 58–65 HRC — impossible by conventional means.

✈️

Titanium & Superalloys

Ti-6Al-4VInconel 718Hastelloy C-276WaspaloyRené 41

Aerospace structural parts, medical implants, and high-temperature engine components. EDM eliminates work-hardening and machining stress concentration issues.

💎

Carbides & Conductive Ceramics

Tungsten CarbideSiCBoron CarbideTiB₂

Ultra-hard wear parts, cutting tool inserts, nozzles, and guide elements. EDM is the only practical precision machining method for these materials at commercial scale.

🔌

Copper, Brass & Alloys

C110 CopperC360 BrassBeCuPhosphor Bronze

EDM electrodes, electrical connectors, heat sinks, and RF shielding. Complex precision geometries machined from solid billets with minimal material waste.

🌟

Stainless Steels

303/304316L17-4 PH440C2205 Duplex

Medical devices, food processing equipment, marine hardware, and pharmaceutical components requiring ISO 10993 biocompatible certification.

⚙️

High-Speed Steels

M2M42T15ASP 2023

Broaches, form tools, gear cutters, and hobs. Post-hardening EDM avoids thermal distortion — parts machined to final dimensions after full hardening cycle.

Physics of EDM

How EDM Creates Micron Precision

Understanding the discharge physics helps engineers design better EDM parts — leveraging unique advantages in materials, geometry, and surface integrity.

Plasma Channel Formation at 8,000–12,000°C
Each spark ionizes dielectric fluid to form a plasma channel exceeding the temperature of the sun's photosphere. Material vaporizes and is expelled within microseconds across a precisely controlled 0.02–0.05mm gap.
200,000 Sparks Per Second — Controlled Erosion
Modern EDM generators fire up to 200kHz pulse sequences. Each removes a microscopic material crater of 0.001–0.1mm³. Millions of controlled erosion events build up the final precision geometry.
Adaptive Servo — 50,000 Gap Samples/Second
Closed-loop digital servo systems monitor inter-electrode gap voltage continuously, adjusting electrode position in real-time to maintain optimal spark conditions and prevent arc instability or wire breakage.
Precision Dielectric Flushing & Thermal Control
High-pressure deionized water flushes eroded particles from the spark gap, re-establishes dielectric breakdown conditions between pulses, and maintains isothermal workpiece conditions for dimensional stability.
Post-Processing

EDM Surface Finishes & Secondary Operations

Complete part finishing under one roof — from as-EDMed surfaces to mirror polish, coatings, and laser marking. No need for secondary suppliers.

As-EDMed Finish

Consistent matte texture, burr-free surfaces, recast layer present. Ra 0.8–3.2µm. Ready for tooling, fixtures, and structural applications where cosmetics are secondary to geometry.

Polishing & Lapping

Hand polishing or vibratory lapping achieves Ra <0.1µm mirror finish. Critical for optical mold surfaces, plastic injection cavities, and FDA-compliant medical implant surfaces.

Passivation & Electropolish

Removes EDM recast layer (white layer), improves corrosion resistance, eliminates stress concentration zones. Essential for aerospace qualification and medical device regulatory compliance.

PVD / CVD Coatings

TiN, TiAlN, DLC, and CrN coatings applied post-EDM for enhanced surface hardness, reduced friction coefficient, and extended tool life in forming and cutting applications.

Post-EDM Heat Treatment

Stress-relief tempering cycles restore bulk material properties after EDM. Prevents micro-cracking in hardened steels and maintains long-term dimensional stability under cyclic loading.

Laser Marking & Kitting

Permanent part identification, serial numbers, and customer logos via fiber laser marking. Sub-assembly, custom kitting, and cleanroom-compatible individual packaging available.

MetalworksPlus EDM facility with advanced precision machining equipment and quality control
15+
Years EDM Expertise
500+
Active Global Customers
50+
Countries Served
24h
Quote Response
Why Choose Us

Why Engineers Trust MetalworksPlus for Precision EDM

We're not a job shop that does EDM on the side. EDM is our core competency — with dedicated machines, dedicated EDM application engineers, and deep expertise spanning aerospace, medical, automotive, and precision tooling.

01
Dedicated EDM Engineering Team — Not Just Operators
In-house EDM application engineers review every RFQ for DFM feedback, electrode design, and cutting strategy optimization — helping you design parts that EDM better, faster, and cheaper.
02
In-House Electrode Manufacturing
We design and manufacture graphite and copper electrodes in-house on our CNC machining center — enabling faster sinker EDM turnaround, lower total cost, and complete electrode geometry control for complex 3D cavity work.
03
Transparent, Fully Documented Quality
Every EDM order ships with a Zeiss CMM inspection report, dimensional measurement data, and material certifications. First Article Inspection per AS9102 available for all aerospace and defense programs.
04
Scalable — Prototype to Production, No MOQ
One prototype or 10,000 production parts — identical quality standards, same engineering attention, guaranteed tolerances at every quantity. No minimum order requirement. JIT supply agreements available.
ISO 9001:2015
ITAR Registered
AS9102 FAIR
Zeiss CMM
Industries Served

EDM Applications Across Key Industries

From flight-critical aerospace components to medical device tooling — MetalworksPlus EDM serves the most demanding applications worldwide with ISO-certified precision.

✈️

Aerospace & Defense

Turbine blades, cooling holes, structural slots, ITAR-controlled components, AS9100 programs

🏥

Medical Devices

Surgical instruments, implant components, micro-features, FDA-compliant biocompatible materials

🔧

Tool & Die

Punch-and-die sets, injection mold inserts, extrusion tooling, progressive stamping dies

🚗

Automotive

Injection molds, gear profiles, fuel system components, transmission precision parts

⚡

Electronics & Semiconductor

Precision connectors, lead frames, test fixtures, heat spreaders, RF shielding

Success Stories

EDM Case Studies — Real Engineering Results

Complex precision EDM challenges solved by the MetalworksPlus engineering and manufacturing team across industry verticals.

✈️ Aerospace

Turbine Blade Film Cooling Holes — Inconel 718

Challenge: 120 × Ø0.3mm holes at compound angles in Inconel 718 — conventional drilling impossible without deflection and progressive work-hardening.
Solution: High-speed EDM drilling with rotating tube electrodes. 5-axis positioning for compound entry angles, auto electrode wear compensation algorithm enabled.
Result: 100% hole position accuracy (±0.015mm), zero recast layer non-conformances, delivered in 8 business days.
Ø0.3mm
Hole Diameter
120 Holes
Per Blade
8 Days
Lead Time
🔧 Tool & Die

Progressive Die in D2 Steel — 62 HRC

Challenge: Complex punch and die plate in fully hardened D2 (62 HRC) with R0.05mm corner radii impossible to achieve by grinding alone.
Solution: Wire EDM with 3 skim passes achieving Ra 0.4µm on all punch faces. Taper angles for clearance built directly into the wire cutting path.
Result: 50% longer tool life vs. previous supplier, reduced burrs on stamped parts, zero rework at first article inspection.
62 HRC
Material
Ra 0.4µm
Surface
+50%
Tool Life
🏥 Medical

Surgical Instrument Mold Cavity — Mirror Finish

Challenge: Injection mold cavity with 0.2mm micro-features and mirror finish required for surgical-grade plastic instrument handle production.
Solution: Sinker EDM with fine graphite electrodes (ISO Grade 8 setting) followed by manual polishing to Ra 0.05µm optical-grade surface quality.
Result: FDA-compliant surface integrity, zero sink marks on molded parts, consistent quality through 12-week production run.
Ra 0.05µm
Final Finish
±0.008mm
Tolerance
FDA
Compliant
⚡ Electronics

Tungsten Carbide Extrusion Die — 89 HRA

Challenge: Complex profile die in WC-Co grade carbide (89 HRA) — no conventional machining method could achieve the required 0.006mm profile accuracy.
Solution: Wire EDM with carbide-specific discharge parameters (optimized pulse energy, flushing pressure), 4 skim cuts for final profile refinement.
Result: ±0.006mm profile accuracy achieved, die service life 3× longer than previous HSS version, zero cobalt leaching issues.
89 HRA
Carbide Grade
±0.006mm
Accuracy
3×
Die Life
Service Offerings

EDM Services — Prototype to Production

Flexible EDM service models designed around your production requirements — from urgent 3-day prototypes to certified JIT production supply agreements.

Custom Parts

Custom EDM Components & Tooling

Complete precision EDM from drawing to finished part — electrode design, wire EDM profiling, sinker cavity work, EDM drilling, and secondary finishing. Full DFM support for optimal manufacturability and cost.

  • No minimum order — 1 piece to high volume
  • Wire EDM prototypes in 3–5 business days
  • Complex 3D cavities, sharp internal corners, deep slots
  • Tolerances to ±0.005mm, Ra to 0.2µm
  • In-house electrode design and CNC manufacturing
  • Full CMM inspection report on every delivery
Request Custom Quote
Production Supply

Production EDM & JIT Supply

Recurring production runs for punches, dies, gears, and precision inserts. JIT delivery scheduling, SPC process control, and certified first articles per AS9102. Electrode library management for fast repeat order turnaround.

  • Production turnaround: 5–10 business days
  • Volume pricing and blanket order agreements
  • SPC reports, Cpk analysis, statistical control
  • Electrode library stored for instant repeat orders
  • DDP shipping worldwide — 50+ countries
  • ISO 9001:2015 certified supply chain
Contact for Production EDM
FAQ

Frequently Asked Questions

Common technical and commercial questions about our EDM services answered by our application engineering team.

Wire EDM (Electrical Discharge Machining) uses a continuously-moving brass or copper wire electrode (0.02–0.30mm diameter) to cut through electrically conductive metal workpieces using controlled electrical spark discharges. The wire never physically contacts the workpiece — material is removed by spark erosion in a dielectric fluid bath, enabling micron-precision cuts with zero cutting force. Tolerances to ±0.005mm and surface finishes to Ra 0.2µm are achievable.
Any electrically conductive material can be EDM machined regardless of hardness. This includes tool steels (D2, H13, M2), titanium alloys (Ti-6Al-4V), superalloys (Inconel 718, Hastelloy, Waspaloy), tungsten carbide (up to 90 HRA), stainless steels (316L, 17-4 PH), copper, brass, and high-speed steels. EDM is the preferred method for materials too hard to machine conventionally — hardness is never a limiting factor.
Wire EDM achieves ±0.005mm (0.0002") precision tolerance verified by Zeiss CMM. Sinker EDM achieves ±0.008mm. EDM drilling achieves ±0.01mm positional accuracy. GD&T True Position capability is ±0.003mm. Surface finish ranges from Ra 0.2µm (mirror, multiple skim passes) to Ra 3.2µm (as-EDMed). These tolerances are maintained consistently across production runs with SPC process control.
We accept STEP (.stp/.step), IGES (.igs/.iges), DWG, DXF, PDF engineering drawings, and all major CAD formats. For sinker EDM cavities, 3D STEP files are preferred for electrode design. For wire EDM, 2D DXF profiles are sufficient. Our engineers will review your files for EDM feasibility and provide DFM feedback with every quotation at no charge.
Standard lead times: Wire EDM prototypes 3–5 business days; Sinker EDM with electrode manufacturing 5–8 days; EDM drilling 3–5 days; Production runs 5–10 days. Rush service available for time-critical programs. We guarantee 24-hour quote response on all EDM RFQs. DHL/FedEx/freight shipping worldwide with DDP terms available for 50+ countries.
Yes. MetalworksPlus is ISO 9001:2015 certified and ITAR registered. We provide AS9102 First Article Inspection Reports for aerospace and defense programs. Every order ships with full CMM inspection documentation, material certifications, and dimensional measurement data. Traceability is maintained throughout our supply chain from raw material to finished delivery.
Get Started

Start Your EDM Project
Today

Upload your CAD files or send specifications — 24-hour quote response guaranteed. Our EDM application engineers personally review every inquiry to provide DFM feedback, realistic tolerances, and competitive pricing.

+86-134-8064-5108  WhatsApp / WeChat nicole.huang@metalworksplus.com
Shenzhen, China — ISO 9001:2015 · ITAR Registered
24h quote response on all EDM RFQs
Accepts STEP · IGES · DWG · DXF · PDF
⚡
3–5 Days
Wire EDM Prototypes
🔧
5–8 Days
Sinker EDM + Electrode
🏭
5–10 Days
Production Runs
🌍
DDP Ship
50+ Countries

📐 Request an EDM Quote

Upload your 3D CAD file or 2D drawing. We'll review EDM feasibility and provide pricing with DFM feedback within 24 hours.

Attach files on the quote page — STEP, IGES, DWG, DXF, PDF accepted