Fathom provides nationwide access to precision wire EDM cutting services using state-of-the-art cutting machines. Whatever your project may be, we have a cutting solution to meet the goal. Discover more about Fathom and the overall advantages of EDM.
Manufacturing engineers turn to EDM (electrical discharge machining) when milling, turning and grinding aren’t up to the task. It’s as if it’s a binary choice: if machining isn’t possible then chose EDM.
The reality is more complex. There’s a significant middle ground where EDM and conventional machining processes go head-to-head. Yes, the wire EDM cutting rate is lower than that milling or turning, but the process scores in other ways. Finished part geometry, workpiece hardness, surface finish and cost are all areas where conventional and EDM compete. Here’s a look at the advantages and limitations of EDM.
With EDM there are no cutting forces and neither tool nor workpiece rotate. In addition, wire EDM is done with wire typically 0.010” diameter. This all means:
Material hardness has little effect on EDM wire cutting rate and doesn’t limit possible part geometries. Tungsten carbide, tool steel, Inconel and any metal harder than RC38 are all good candidates where conventional machining is slow and expensive.
A particular benefit is the ability to bring parts to their final size after heat-treatment. This takes out distortion brought about by hardening and stress-relieving.
Unlike conventional processes, an EDM surface has a very random texture. This is advantageous when directionality or “lay” could influence product performance. Additionally, EDM can create surface finishes as smooth as 5 RMS or around 4 micro-inches Ra. (This entails taking multiple skimming passes, for which the wire EDM cutting rate needs to be very low.)
On the right job – complex 2D geometry, hard material – EDM offers cost savings over conventional processes. For example:
EDM requires an electrically conductive workpiece. It will not work on wood, plastics or composites.
Material removal rates (MMR) are usually lower than for conventional processes. However, direct comparisons are difficult to make since material hardness is such a big factor. MMR is usually calculated in cubic inches per hour with 0.4 in3/hr a typical rate. Calculated this way, a narrow kerf makes the wire EDM cutting rate quite high. Also, workpiece thermal conductivity and melting point have significant impacts on EDM MMR.
Wire EDM can only cut 2D profiles, although a fourth axis to incline the wire enables conical forms and tapers.
EDM is more than just a fall-back for when conventional machining isn’t up to the task. It’s a process to consider whenever the workpiece is hard, electrically conductive, and has specific geometric challenges or surface finish requirements.
Are you ready to learn about manufacturing services such as wire EDM? Fathom’s SmartQuote online platform is the quickest way to receive a quote in as little as 1 hour, usually within 24 hours. Fathom’s wire EDM lead times are as follows:
Thousands of companies rely on Fathom for their wire EDM projects. For both low- and high- volume projects, Fathom can utilize its single-source global network to finish your job quickly. Fathom produces high-quality parts by leveraging both additive and advanced technologies.
Wire EDM is one of 28 manufacturing processes offered by Fathom.
Fathom’s global network includes over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Thirty-one of Fathom’s machines are utilized for EDM manufacturing with 16 for wire EDM, 12 for sinker EDM and 3 for drill EDM. Fathom’s network of state-of-the-art equipment allows us to deliver high-quality parts with a quick turnaround.
Fathom’s production capabilities include hybridized services that leverage wire EDM. Does your complex project require wire EDM? Fathom can help. A recent case study illustrates how Fathom manufactured 20,000 parts in 27 days using 55+ tools, including water jet cutting services.:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
Fathom has 5 US-based locations that offer wire EDM, offering nationwide coverage to the entire United States. Fathom’s advanced prototyping and manufacturing services include injection molding, CNC machining, chemical etching, metal 3D printing, and more. We have provided over 200,000 quotes to leading U.S. companies and are ready to provide you with a quote today.
Wire EDM locations include:
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST 800-171 Compliant
ITAR
FLORIDA
14000 N.W. 58th Court
Miami Lakes, FL 33014
ISO 9001:2015 Design Certified
ISO 13485:2016
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified
TEXAS
1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016
Wire EDM offers great precision, even when used with hard raw materials. Tighter tolerances and higher cutting accuracies are possible with Wire EDM. To improve accuracy, lower speed and power may be used. Reduced power and flushing pressure results in +/- 0.0005” tolerance.
| Material Thickness | Tolerance | Kerf | Part Volume | Set Up Cost | Lead Time ** | Notes |
|---|---|---|---|---|---|---|
| 0.001″ – 6″ | 0.0005″ | 0.005″ | 1-200 Is Best | Low | 6-8 days | Conductive Metals, Carbon |
Wire EDM should be used with any conductive metal such as titanium, aluminum, brass, alloys, and superalloys. Thanks to wire EDM’s accuracy, wire EDM has become a popular manufacturing method for various industries. Whether for part or prototype, Fathom has many materials suitable for wire EDM, including:
Wire EDM is used to produce a smooth, mirror-like finish, but some finishing may still be required to customize a part. Common finishing processes that can be used for wire EDM parts include:
Painting a part adds color, varnish, or ink. The painting process may include powder coating, liquid coating, or e-coating. Powder coating uses an electrostatically charged powder which produces a scratch-resistant and uniform coat on the metal part. When a part is liquid coated, wet paint is applied. The e-coating process involves dipping the part into a bath of paint where both the part and paint are electrified, causing the paint to adhere to the part.
Transfers apply a label or design to a part. During the transfer process, a design is placed onto the part and pressure is applied through a heated press. Transferring can also be used to print a design that may later be engraved onto the part.
Assembly is needed if a part is produced in smaller units that must be pieced together to form a larger product. During assembly, the workpiece is bonded together with other parts to form the final product. Bonding procedures or fasteners may be used to fuse parts permanently or temporarily.
Drilling adds a round hole to a part. Drill presses, tapping, or a milling machine may be used to drill. Different types of drills may be used including peck drills or spotting, depending on the type of mark required.
Deburring removes raised edges or burrs from a part. Electrochemical deburring, thermal deburring or abrasive flow deburring may be used to deburr a part. Electrochemical deburring uses an anodic metal dissolution to remove unwanted material. Thermal deburring uses a combustible gas in a pressurized chamber to deburr a part. Abrasive deburring uses an abrasive slurry to deburr the part.
A: Yes, Fathom offers wire EDM machining.
A: Wire EDM is the process of machining metal that uses a tool to discharge sparks onto metal material. The discharge melts the material, creating an accurate cut.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: The applications of wire EDM include internal gear, miniature parts, small hole drilling, extrusion molds, tools, progressive stamping dies, medical devices, aerospace parts and more.
A: Wire EDM can produce patterns and shapes previously unachievable using conventional tools. Hard materials do not affect wire EDM’s cutting rate or ability to create complex geometric shapes. Wire EDM is not used if the raw material selected is not electrically conductive. Wire EDM can only cut 2D profiles and the material removal rate is lower than with conventional cutting methods.
A: Wire EDM should only be used on materials that are electrically conductive. Wire EDM is only used for parts that require a 2D profile. The material removal rate of Wire EDM is lower than other conventional cutting processes.
A: Wire EDM is not considered a sustainable manufacturing method due to high energy use and hazardous emissions.
Are you ready to start your wire EDM project? Use Fathom’s SmartQuote application to receive a fast quote on any file.
Precision manufacturing
from coast to coast.
HEADQUARTERS //
1050 Walnut Ridge Drive
Hartland, WI 53029
877-328-4668
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
480-966-2300
CALIFORNIA
46758 Lakeview Blvd
Fremont, CA 94538
COLORADO
7770 Washington St.
Denver, CO 80229
303-288-6855
FLORIDA
14000 N.W. 58th Court
Miami Lakes, FL 33014
305-889-3280
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
815-385-7500
1401 Brummel Ave
Elk Grove, IL 60007
847-952-8088
MINNESOTA
13758 Johnson Street NE
Ham Lake, MN 55304
763-755-7575
NEW YORK
1920 Slaterville Rd.
Ithaca, NY 14850
607-277-7070
401 W. Shore Blvd.
Newark, NY 14513
315-331-7680
TEXAS
1513 Sam Bass Rd.
Round Rock, TX 78660
512-255-1477
