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Wire EDM Cost

  • Cost Effective Manufacturing Option
  • Production-Grade Repeatablity
  • Ideal for Complex, Small-Scale Designs
Quotes for 25+ Manufacturing Processes.
Wire EDM Services
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Complex Parts
Cost Effective
Set Up & Production
Wire EDM Cost

Using wire EDM technology, Fathom delivers high-quality parts to its customers. Whether your project is time-sensitive, high-precision, highly complex, or short production run related, Fathom will meet your requirements.

Details Considered for Quoting a Wire EDM Job / /

Design, material, quantity ordered, and turnaround time all factor into the cost of wire EDM.


Complex geometric and intricate shapes can be machined with a high level of accuracy using wire EDM. The wire EDM machine makes no contact and does not place pressure on the material, allowing thin metal sections to be cut. Wire EDM eliminates any stress or distortion. A fine finished is produced which eliminates the need for finishing procedures.


Even the hardest raw materials can be cut using wire EDM. As the material does not need to be heat treated, solid pieces of metal can be machined without distortion. Any heat applied to the raw material is minimal and quickly removed by dielectric fluid.


The volume of parts needed is also factored into the cost of wire EDM. Costs can be reduced by stacking parts during cutting, which saves time. Quotes are often based on the time a job takes on the cutting machine.

Turnaround Time

Wire EDM is a cost-effective manufacturing process. As wire EDM is an automated method, labor and time are reduced. Lead time is also minimized as custom tooling is not needed. EDM produces smooth parts which means there is no need for finishing or secondary steps. As finishing is not necessary, the part can be made quickly.

Wire EDM Cost Quote Times / /

Receive a quote in as little as 1 hour using Fathom’s SmartQuote online platform. Are you ready for a wire EDM quote? Do you want to learn more about another manufacturing service? Fathom’s wire EDM lead times are as follows:

  • Parts as fast as 6-8 days

Wire EDM Services Offered by Fathom / /

Work with Fathom on your wire EDM job. Fathom’s single-source global network will support your low- and high-volume projects. By leveraging both additive and advanced technologies, Fathom can produce high-quality parts that will satisfy customers.

Wire EDM is one of 28 manufacturing processes offered by Fathom.

Additive Manufacturing

  • FDM
  • SLS
  • SLA
  • Polyjet
  • MJF
  • DMLS
  • DLS
  • STEP (Evolve)

CNC Machining

  • CNC (3 & 5 Axis)
  • CNC Lathe
  • Precision Grinding
  • Wire & Sinker EDM

Injection Molding

  • Injection Molding
  • Tooling
  • Compression Molding

Metal Cutting and Forming

  • Thermoforming
  • Sheet Metal Punching
  • Sheet Metal Cutting
  • Metal Forming
  • Laser Cutting
  • Water Jet Cutting
  • Chemical Etching
  • Welding
  • Micro Cutting


  • Die Casting
  • Urethane Casting
  • Composite Layups
  • Extrusion
  • Post Processing & Finishing
    • Pad Printing
    • Powder Coating
    • Bead Blasting
    • Surface Grinding
    • Polishing
    • Anodize
    • Powder Coat Passivate
    • Chemfilm
    • Vacuum Metallization
    • Silkscreen
    • Plating
    • Tumbled

Wire EDM Machines Used by Fathom / /

Thirty-one of Fathom’s machines are used for EDM manufacturing, including 16 for wire EDM, 12 for sinker EDM, and 3 for drill EDM. Fathom’s manufacturing network includes over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Fathom’s network of state-of-the-art equipment allows us to offer our customers a rapid turnaround.

In addition to wire EDM, Fathom also offers hybridized services. Does your 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.:

Case Study //

Real Customers. Real Results.

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.

20,000 Parts // Within 27 Days
55+ Tools to Injection Mold 15,000 Parts First Article in 2 Weeks

55+ Tools to Injection
Mold 15,000 Parts

First Article in 2 Weeks

3,000+ 3D Printed Parts

3,000+ 3D
Printed Parts

2,000+ Metal Fabricated Parts

2,000+ Metal
Fabricated Parts

Hybridized Services Used //

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’s Locations for Wire EDM / /

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:

444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST 800-171 Compliant

14000 N.W. 58th Court
Miami Lakes, FL 33014
ISO 9001:2015 Design Certified
ISO 13485:2016

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified

1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016

Wire EDM Specifications and Tolerances / /

Tighter tolerances and higher cutting accuracies can be achieved using wire EDM. To improve the accuracy of wire EDM, a lower power and speed can be used. By reducing the power and flushing pressure results in +/- 0.0005” tolerance. Wire EDM provides great precision, even when working with the hardest of raw materials.

Material Thickness Tolerance Kerf Part Volume Set Up Cost Lead Time ** Notes
up to 15.750 inches thick 0.0005" 0.006" 1-200 Is Best Low 6-8 days Conductive Metals, Carbon

Wire EDM Materials List / /

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:

  • Copper
  • Carbide
  • Tungsten
  • Bronze
  • Carbon steel
  • Inconel
  • Stainless steel
  • Hastalloy
  • Kovar
  • Titanium
  • Carbon graphite
  • High alloy steel

Advantages of Wire EDM / /

There are many advantages to wire EDM. Since wire EDM uses an electrically charged wire to cut shapes, it can cut pieces from fragile and hard materials. Manufacturing involves little to no impact or pressure on the raw material making it possible to manufacture brittle parts. Wire EDM enables higher accuracy and is more precise than laser or plasma cutting. As a one-step process lead time is reduced. The quick turnaround time and minimal waste make wire EDM a cost-effective method.

Wire EDM Finishing Processes / /

Wire EDM produces a mirror-like, smooth finish, but some customization may still be required. Common finishing processes used on wire EDM parts include:


Powder coating, liquid coating, or e-coating are all painting methods. The powder is electrostatically charged during powder coating, leaving a scratch-resistant and even coat on the metal part. Liquid coating applies wet paint to a surface. E-coating is the process of dipping a metal part into a bath of paint. The part and paint are electrified, and the paint adheres to the part. Painting is used to add color, varnish, or ink to a part.


During transfer, a design is placed onto the part, pressure is applied using a heated press, and the design is transferred. This method can also be used to print a design that will later be engraved.


During assembly, the workpiece is bonded together with other parts to create the final product. Fasteners or bonding procedures may be used to fuse the parts temporarily or permanently. Assembly is required when the unit manufactured is part of a larger piece.


Drilling may be performed using a drill press, tapping, or milling machine. Different types of drills may be used, such as spotting or peck drills, depending on the mark that must be made. Drilling is used to add a round hole.


Deburring may be achieved using several methods, including electrochemical deburring, thermal deburring, and abrasive flow deburring. 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 flow deburring uses an abrasive slurry to deburr the part. Deburring is used to remove any raised edges or unwanted material known as burrs.

Examples of Wire EDM Parts / /

The automotive, aerospace, electronic industries and more all use wire EDM manufacturing. Wire EDM is a highly accurate process capable of outstanding feature resolutions using fragile and hard materials. Examples of wire EDM parts are:

  • Internal gear
  • Titanium needles
  • Miniature parts
  • Extrusion dies
  • Blanking punches
  • Small hole drilling
  • Extrusion molds
  • Tools
  • Progressive stamping dies
  • Medical devices
  • Aerospace parts
  • Automotive parts
  • Robotics

Wire EDM Cost FAQs / /

Q: Does Fathom offer Wire EDM machining?

A: Yes, Fathom offers wire EDM machining.

Q: What is 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.

Q: Is Fathom ISO certified?

A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016.

Q: Is Fathom ITAR certified?

A: Yes, Fathom is ITAR certified.

Q: Is Fathom AS9100:2016 certified?

A: Yes, Fathom is AS9100:2016.

Q: Is Fathom NIST 800-171 certified?

A: Yes, Fathom’s certifications include NIST 800-171.

Q: Why is wire EDM so expensive?

A: The cost of wire EDM largely depends on the complexity of design, quantity ordered, material selected, and the turnaround time.

Q: How do you calculate wire EDM time?

A: Wire EDM machining time is the periphery of the part divided by the average linear feed rate (ALF).

Q: What is wire EDM used for?

A: Wire EDM is used to manufacture parts using hard or brittle materials that are unable to be manufactured using traditional methods.

How to Get Wire EDM Cost / /

Ready for a wire EDM quote? Do you want to know the cost of an upcoming project? Fathom’s SmartQuote application provides fast cost for any file. Receive a quote in as little as one hour.

Across National
Time Zones

Precision manufacturing
from coast to coast.

1050 Walnut Ridge Drive
Hartland, WI 53029

444 W. 21st St. Ste. 101
Tempe, AZ 85282

46758 Lakeview Blvd
Fremont, CA 94538

7770 Washington St.
Denver, CO 80229

14000 N.W. 58th Court
Miami Lakes, FL 33014

1207 Adams Drive
McHenry, IL 60051

1401 Brummel Ave
Elk Grove, IL 60007

13758 Johnson Street NE
Ham Lake, MN 55304

1920 Slaterville Rd.
Ithaca, NY 14850

401 W. Shore Blvd.
Newark, NY 14513

1513 Sam Bass Rd.
Round Rock, TX 78660

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