Injection Molding
Tooling and molding for your repeat plastic parts.
PRECISION WIRE EDM MACHINING
Wire EDM Services for Your High-Precision Parts.
Build your cut around geometry, material and critical features.
Review intricate profiles, narrow slots and hardened conductive materials before production. Align your wire-cut part with the fit, surface condition and inspection evidence your assembly needs.
Complex Through-ProfilesSmall Internal RadiiHard Conductive MaterialsNo Mechanical Cutting ForcePrototype to Repeat Orders
WIRE EDM OVERVIEW
Build Your Cut Around Your Critical Features
Wire electrical discharge machining erodes conductive material with controlled electrical discharges from a travelling wire. Review through-profiles, internal radii and access before choosing the process.
- Cut intricate through-profiles and narrow slots
- Review hardened materials without a conventional cutting tool
- Protect thin features from mechanical cutting loads
- Define start holes, taper and removal of cut-out material
- Agree finish passes and inspection for your drawing
OUR WIRE EDM SERVICES
Choose the Review for Your Part
Connect Your Profile to a Practical Cut Plan
Review the complete through-profile, stock thickness and start-hole access. A clear cutting route helps protect your finished geometry.
- Your internal and external profiles
- Start-hole position and wire access
- Stock condition and finished datums
Protect Your Mating Features
Identify the dimensions that control fit and the reference surfaces used in assembly. Agree the cut strategy and measurement method together.
- Critical dimensions and internal radii
- Rough and finish pass strategy
- Drawing-based inspection
Review Your Top and Bottom Profiles
Taper feasibility depends on part height, wire guidance and geometry. Supply both profiles or a complete model so the angle and access can be reviewed.
- Top and bottom geometry
- Part height and taper direction
- Acceptance method for angled walls
Make Your Small Features Measurable
Narrow slots and small internal radii need a review of wire size, discharge gap, flushing and part support. Confirm achievable features for your specific drawing.
- Minimum slots and corner radii
- Fragile feature support
- Optical or other suitable measurement
Control Your Functional Tooling Profiles
Coordinate heat treatment, datum preparation and wire cutting for punches, die inserts and other tooling components. Define the final surface requirement.
- Grade and heat-treatment condition
- Profile clearance and mating geometry
- Surface integrity and inspection scope
Validate Your Geometry Before Repeat Orders
Use the first cut to confirm fit, profile and the agreed inspection plan. Identify which features need functional testing by your team.
- Prototype quantity and test purpose
- Critical dimensions and records
- Approved revisions for the next release
Carry Your Approved Profile into Each Lot
Set the controlled drawing, material condition and batch acceptance requirements before repeat supply. Coordinate identification and packaging with your receiving team.
- Approved drawing and process scope
- Lot records and sampling plan
- Scheduled quantity and delivery
PREVENT WIRE EDM ISSUES BEFORE PRODUCTION
Resolve Your Cut Risks Before the First Part
Select a topic to see the review focus and the benefit for your program.
Keep Your Internal Corners on Spec
The wire diameter and discharge gap create a minimum internal radius. Define the radius your mating part can accept; a perfectly sharp internal corner is not a standard wire-cut result.
- Specify functional internal radii
- Review wire size and discharge allowance
- Check mating clearances and inspection
Your Project Benefit
Avoid a profile that cuts cleanly but does not fit.
Give Your Wire a Clear Entry
Closed internal profiles need a suitable start hole or another agreed threading route. Keep the entry away from finished functional surfaces where practical.
- Hole size and threading access
- Entry path relative to the final profile
- Preparation before heat treatment or cutting
Your Project Benefit
Reduce avoidable setup changes and witness marks.
Review the Conditions Behind a Stable Cut
Material condition, part height, flushing and cut settings influence wire stability. Review interruptions and changes in section with the process plan.
- Section thickness and interrupted paths
- Flushing access and fixture clearance
- Material condition and cut sequence
Your Project Benefit
Reduce interruptions and inconsistent surfaces.
Control the Wall Your Part Needs
Align top and bottom geometry with the specified datum and part height. Specify intentional taper separately from straightness or perpendicularity requirements.
- Top and bottom dimensions
- Datum alignment and part height
- Measurement of the angled or straight wall
Your Project Benefit
Protect the intended fit across the full thickness.
Support the Cut-Out Before It Releases
Plan retention and removal of internal cut-outs so they do not shift into the wire or damage a finished surface. Review fragile and nested geometry early.
- Cut-out weight and release sequence
- Retention and removal access
- Protection of finished edges
Your Project Benefit
Protect your part during the final separation.
Agree the Surface Your Application Needs
EDM is a thermal process. Specify roughness and any surface-integrity requirements so finish passes or secondary processing can be included when needed.
- Required surface roughness
- Recast or integrity requirements where applicable
- Finish passes and secondary treatment
Your Project Benefit
Avoid discovering a surface requirement after cutting.
CHOOSE YOUR MANUFACTURING ROUTE
Choose the Right EDM Solution for Your Part
Compare the geometry you need—not a universal process ranking.
| Decision | Wire EDM | Sinker EDM | CNC Machining |
|---|---|---|---|
| Feature access | Through-profiles; a wire path is required | Blind cavities and accessible electrode geometry | Depends on cutting-tool access |
| Material | Electrically conductive materials | Electrically conductive materials | Broad metal and plastic selection |
| Cutting action | Electrical erosion; no mechanical cutting force | Electrical erosion; no mechanical cutting force | Mechanical cutting with a tool |
| Internal geometry | Small radii limited by wire and discharge gap | Electrode-dependent cavity shape | Tool-diameter and access limits |
| Tooling decision | Wire, fixtures and start-hole preparation | Custom electrodes and fixtures | Cutting tools and fixtures |
| Surface review | Finish passes and surface integrity | Electrode and discharge settings | Tool marks and finishing plan |
| Best starting point | Intricate conductive through-profiles | Conductive blind cavities | Accessible features and broader geometry |
MATERIALS FOR YOUR WIRE-CUT PART
Confirm Your Grade and Condition
Electrical conductivity is required. Exact grade, heat treatment, thickness and surface requirements govern the review.
Tool Steel
Your hardened tooling and wear interfaces.
Stainless Steel
Your grade, corrosion and finish requirements.
Titanium
Your alloy and surface-integrity requirements.
Aluminum
Your alloy, temper and thin-feature stability.
Copper / Brass
Your conductive components and profile details.
Conductive Carbide
Review binder, grade and edge integrity.
FROM DESIGN TO PRODUCTION
Keep Your Approval Steps Clear
01 · CAD & Drawing Review
You specify geometry, material and quantity.
02 · DFM / Cut Plan
Review access, radii, support and finish passes.
03 · First Cut
Validate your agreed sample geometry.
04 · First Article Review
Review your specified dimensions and records.
05 · Production Approval
Release your controlled revision and quantity.
06 · Repeat Delivery
Receive identified, protected parts to the agreed plan.
FROM STOCK TO YOUR FINISHED PART
Plan the Operations Around Your Geometry
Raw Material
Confirm grade and condition.
Start-Hole Prep
Prepare the threading route.
Wire EDM Cut
Form your through-profile.
Finish Passes
Reach the agreed geometry and finish.
Secondary Work
Deburr or treat where specified.
Inspection
Verify your critical features.
Finished Part
Identify and protect for delivery.
QUALITY BUILT INTO YOUR CUT
Match Inspection to Your Drawing
Agree inspection methods and documentation before production.
Start with Your Specified Stock
Confirm the required grade, heat-treatment condition and available material documentation.
- Your critical dimensions and datums
- Your agreed material and lot records
- Your specified surface and edge condition
Agree Your First-Part Evidence
Review critical profile dimensions against your datums before release to repeat production.
- Your critical dimensions and datums
- Your agreed material and lot records
- Your specified surface and edge condition
Check the Features That Control Fit
Use suitable dimensional or optical methods and an agreed sampling plan for your geometry.
- Your critical dimensions and datums
- Your agreed material and lot records
- Your specified surface and edge condition
Release Your Part with the Agreed Records
Verify specified profile, surface and identification requirements before protected packaging.
- Your critical dimensions and datums
- Your agreed material and lot records
- Your specified surface and edge condition
WIRE EDM APPLICATIONS
Support the Profiles Your Product Depends On
Tool & Die
Your punches and matched die profiles.
Instrument Components
Your drawing-controlled fine features.
Electrical Components
Your conductive profiles and contacts.
Industrial Automation
Your precise locating and fitted interfaces.
Dallas-Area Support
- Your engineering discussion
- Clear project updates
- Visits by appointment
Engineering → Production
Quality → Delivery
Quality → Delivery
Manufacturing in China
- Your approved process plan
- Agreed inspection and records
- Your scheduled release
What to Send for Your Wire EDM Quote
- STEP / STP model and controlled PDF drawing
- Material grade and heat-treatment condition
- Part thickness and profile dimensions
- Critical datums, internal radii and GD&T
- Start-hole and through-cut requirements
- Taper, roughness and surface-integrity needs
- Quantity, inspection records and target date
Frequently Asked Questions
What is the minimum internal radius for wire EDM?
The practical radius depends on wire diameter, discharge gap, material and the cut strategy. Mark your functional radius and mating clearance on the drawing so feasibility can be confirmed.
What materials can you wire EDM?
The workpiece must conduct electricity. Tool steels, stainless steels, titanium, aluminum, copper, brass and some carbide grades can be reviewed. Supply the exact grade and condition.
Can wire EDM produce blind cavities?
Standard wire EDM needs a continuous wire path through the workpiece. For blind cavities, review sinker EDM or CNC machining instead.
What tolerances and surface finish can you achieve?
Results depend on geometry, thickness, material, cut settings and finish passes. Your quote should confirm feature-specific tolerances, roughness and the agreed inspection method.
Does wire EDM leave a heat-affected surface?
EDM removes material thermally. If your application has recast-layer or other surface-integrity requirements, specify them so finish passes, secondary treatment and verification can be reviewed.
What affects lead time and cost?
Material and heat-treatment availability, threading preparation, part height, cut length, finish passes, inspection and quantity all affect the plan. The reviewed quotation confirms timing and scope.
Can you provide FAI or PPAP support?
Identify the required report level and records at quotation. First article or production approval documentation is agreed for your program; it is not assumed for every order.
Can you support prototype and repeat orders?
Share the initial quantity, expected repeat demand and release schedule. Sample approval, controlled revisions and lot identification can be planned together.
Your Part Review
Before the First Cut
Confirm your drawing, material condition and acceptance plan.
Before Repeat Orders
Confirm approved samples, revision and release quantity.
Product images illustrate manufacturing concepts, not customer case studies. Your approved drawing and agreed specifications govern supplied parts.
