Electric Discharge
Machining Services
– Wire & Sinker EDM
Precision EDM for complex geometries, hard alloys up to 65 HRC, and tolerances to ±0.005mm. Wire EDM, Sinker EDM, and EDM drilling — from rapid prototypes to high-volume production runs.
What Is Electrical Discharge Machining?
EDM is an advanced non-contact manufacturing process that removes material from conductive workpieces using precisely controlled electrical sparks. Unlike conventional cutting, EDM exerts zero mechanical force on the workpiece — enabling machining of extremely hard materials, intricate 3D cavities, and fragile geometries without distortion or tool deflection.
Controlled Spark Erosion
Electrical discharges (sparks) between the electrode and workpiece vaporize material with micron-level accuracy, controlled by servo systems maintaining a precise 0.02–0.05mm gap.
Dielectric Fluid System
Parts are submerged in dielectric fluid (deionized water or EDM oil) which flushes away eroded particles, cools the workpiece, and controls discharge conditions for consistent quality.
CNC-Controlled Precision
Adaptive servo control continuously adjusts gap distance, pulse frequency, and discharge energy — enabling tolerances to ±0.005mm with repeatability across production runs.
Hardness Is No Barrier
Any electrically conductive material — regardless of hardness — can be EDM machined. Tungsten carbide at 90 HRA, hardened D2 steel at 62 HRC, Inconel 718 — all processed with equal precision.
The EDM Machining Process — Step by Step
From design file to finished precision component — a transparent, quality-driven workflow.
Wire EDM, Sinker EDM & EDM Drilling
Advanced Sodick and Makino machines with adaptive servo control, automated wire threading, and real-time spark optimization.
Wire Electrical Discharge Machining
A continuously-moving brass or copper wire (0.02–0.3mm diameter) serves as the electrode, cutting through conductive workpieces with micron precision. Ideal for through-profiles, complex contours, extrusion dies, and punch-and-die sets.
Sinker / Die-Sinking EDM
A shaped electrode (graphite or copper) is fed into the workpiece to create blind cavities, pockets, and 3D features. The electrode "sinks" into the workpiece, transferring its negative form. Essential for mold cores, blind pockets, cooling channels, and textured surfaces.
Small Hole EDM Drilling
High-speed EDM drilling using rotating tubular electrodes creates extremely deep, high-aspect-ratio holes impossible with conventional drilling. Depth-to-diameter ratios exceeding 50:1. Critical for turbine blade cooling holes, fuel injector nozzles, and wire EDM start holes.
MetalworksPlus EDM Performance Metrics
Verified by Zeiss CMM
Multiple Skim Passes
No Limitation on Hardness
Rapid 3–5 Day Prototypes
Our Workshop & Precision Parts
A glimpse into MetalworksPlus's precision EDM facility — where engineering excellence meets advanced technology.
EDM Tolerances & Metrology Standards
Industry-leading precision backed by traceable measurement systems — Zeiss CMM, Keyence vision systems, and Mitutoyo surface profilometers.
| 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, intricate cutouts, electrical contacts |
| Sinker EDM (Ram) Makino EDAF3 |
±0.015mm | ±0.008mm | 0.4 – 1.2µm | Mold cavities, blind pockets, aerospace cooling channels, medical tooling, electrode forms |
| EDM Drilling High-Speed |
±0.02mm | ±0.01mm | 0.8 – 1.6µm | Cooling holes (turbine blades), fuel nozzles, wire start holes, micro-holes ≥ Ø0.1mm |
| GD&T – True Position AS9102 FAIR |
±0.01mm | ±0.003mm | — | Flight-critical components, alignment features, medical devices, precision fixtures |
All dimensions verified by Zeiss Contura CMM. First Article Inspection (FAIR) reports available per AS9102. Material certifications and full traceability provided on request.
Materials We Machine by EDM
Any electrically conductive material — from soft brass to 90 HRA tungsten carbide — processed with equal precision. Hardness is never a limitation.
Tool & Die Steels
High wear resistance for punch dies, forging tools, injection mold inserts. Typically machined post heat-treatment at 58–65 HRC.
Titanium & Superalloys
Aerospace structural parts, medical implants, and high-temperature engine components. EDM eliminates machining stress concerns.
Carbides & Conductive Ceramics
Ultra-hard wear parts, cutting tool inserts, nozzles, and guide elements. EDM is the only practical machining method for these materials.
Copper, Brass & Alloys
EDM electrodes, electrical connectors, heat sinks, and RF shielding components. Complex geometries machined from solid billets.
Stainless Steels
Medical devices, food processing equipment, marine hardware, and pharmaceutical components requiring high corrosion resistance.
High-Speed Steels
Broaches, form tools, gear cutters, and hobs. Post-hardening EDM avoids distortion — parts machined to final dimensions after full hardening.
How EDM Creates Micron Precision
Understanding the electrical discharge process helps engineers design better parts for EDM — leveraging its unique advantages in materials and geometry.
Plasma Channel Formation
Each spark creates a plasma channel reaching 8,000–12,000°C — hotter than the sun's surface. Material vaporizes in microseconds within a precisely controlled gap of 0.02–0.05mm.
200,000 Sparks Per Second
Modern EDM generators fire up to 200kHz discharge pulses. Each removes a microscopic crater of ~0.001–0.1mm³, building up to the final precision geometry through millions of controlled erosion events.
Adaptive Servo Control
Digital servo systems monitor gap voltage 50,000 times/second, adjusting electrode position in real-time to maintain optimal spark conditions and prevent short-circuits or wire breakage.
Dielectric Flushing
High-pressure dielectric fluid flushes eroded particles from the gap, deionizes the space between discharges, and maintains thermal equilibrium for consistent material removal.
EDM Surface Finishes & Secondary Operations
Complete part finishing under one roof — from as-EDMed surfaces to mirror polish and protective coatings.
As-EDMed Finish
Consistent matte texture, burr-free, recast layer present. Ra 0.8–3.2µm. Ready for tooling, fixtures, and structural applications where cosmetics are secondary.
Polishing & Lapping
Hand polishing or vibratory lapping achieves Ra <0.1µm mirror finish. Critical for optical mold surfaces, plastic injection cavities, and medical implant surfaces.
Passivation & Electropolish
Removes recast layer (white layer) from EDM surfaces, improves corrosion resistance, and reduces stress concentration. Essential for aerospace and medical device compliance.
PVD / CVD Coatings
TiN, TiAlN, DLC, and CrN coatings applied post-EDM for enhanced wear resistance, reduced friction, and extended tool life in forming and cutting applications.
Post-EDM Heat Treatment
Tempering and stress-relief cycles restore material properties after EDM. Prevents micro-cracking in hardened steels and maintains dimensional stability in service.
Laser Marking & Assembly
Permanent part identification, serial numbers, and customer logos via fiber laser. Sub-assembly, custom kitting, and cleanroom-compatible packaging available.
Why Engineers Choose MetalworksPlus for EDM
We're not a job shop that does EDM on the side. EDM is our core competency — with dedicated equipment, dedicated operators, and decades of application expertise across aerospace, medical, automotive, and tooling.
Dedicated EDM Engineering Team
In-house EDM engineers provide DFM feedback, electrode design, and process optimization — not just machine operators. We help you design parts that EDM better.
In-House Electrode Manufacturing
We manufacture our own graphite and copper electrodes — faster turnaround, lower cost, and complete design control for sinker EDM cavities and complex 3D forms.
Transparent, Traceable Quality
Every EDM job ships with a full inspection report, material certifications, and CMM measurement data. No surprises — just verified, documented precision.
Scalable — Prototype to Production
One prototype piece or 10,000 production parts — same quality standards, same engineering attention, same guaranteed tolerances. No MOQ required.
EDM Applications Across Key Industries
From flight-critical aerospace components to medical device tooling — MetalworksPlus EDM serves demanding applications worldwide.
Aerospace & Defense
Turbine blades, cooling holes, structural slots, ITAR-controlled parts
Medical Devices
Surgical tooling, implant components, micro-features, biocompatible materials
Tool & Die Making
Punches, dies, mold inserts, extrusion tooling, progressive dies
Automotive
Injection molds, gear profiles, fuel system components, transmission parts
Electronics & Semiconductor
Precision connectors, lead frames, test fixtures, heat spreaders
EDM Case Studies — Real Results
Examples of precision EDM challenges solved by MetalworksPlus engineering and manufacturing.
Turbine Blade Film Cooling Holes
Progressive Die for Automotive Stampings
Surgical Instrument Mold Cavity
Tungsten Carbide Extrusion Die
EDM Services — Prototype to Production
Flexible EDM service models designed around your production requirements — from urgent prototypes to long-term supply agreements.
Custom EDM Components & Tooling
Complete precision EDM solutions from drawing to finished part — electrode design, wire EDM cutting, sinker cavity work, EDM drilling, and secondary finishing. Full DFM support for optimal manufacturability.
- No minimum order quantity — 1 piece to high volume
- Wire EDM prototypes in 3–5 days
- Complex 3D cavities, sharp corners, deep slots
- Tolerances to ±0.005mm, Ra to 0.2µm
- In-house electrode design and manufacturing
Production EDM & JIT Supply
Recurring production runs for punches, dies, gears, and precision inserts. JIT delivery scheduling, SPC process control, and certified first articles. We maintain electrode libraries for repeat orders to minimize lead times and cost.
- Production turnaround: 5–10 business days
- Volume pricing and blanket order agreements
- SPC reports and statistical process control
- Electrode library management for repeat orders
- DDP shipping worldwide — 50+ countries served
Start Your EDM Project Today
Upload your CAD or send specifications — 24-hour quote response for wire EDM, sinker EDM, and production runs. Our EDM engineers review every inquiry personally.
📐 Request an EDM Quote
Upload .STEP, .IGES, .DXF or .PDF drawings. We'll review EDM feasibility, electrode requirements, and provide competitive pricing with DFM feedback.
💬 Talk to an EDM Specialist
Have a complex geometry, unusual material, or tight deadline? Our application engineers are available via WhatsApp, email, and phone.