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Wire EDM Tolerances

  • 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 Tolerances

Fathom has the latest in wire EDM technology ready to deliver high-quality parts to its customers. Whether your project is time-sensitive, highly complex, high precision, or short production run related, Fathom can meet the requirements of your project.

Wire EDM Specifications and Tolerances / /

Higher cutting accuracies and tighter tolerances are possible with wire EDM technology. Even when working with the hardest of materials, greater precision is possible. To improve cutting accuracy, a lower power and speed can be used. By reducing the power and flushing pressure results in +/- 0.0005” tolerance.

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

How Wire EDM Tolerances Differ from Other Cutting Processes / /

Wire EDM has different tolerances and details compared to other cutting solutions. Discover those differences below.

Material Thickness Tolerance Kerf Part Volume Set Up Cost Lead Time ** Notes
FIBER LASER AL: 0.250″ SS: 0.375″ CRS: 0.500″ COP: 0.250″ Brass: 0.125″ 0.002″ – 0.005″ .008″ 1 to High-Volume Low 6-8 Days Metals – Fast
OMAX WATERJET Up to 6″ 0.005″ – 0.015″ .020″/.040″ 1 to 5000 Low 6-8 Days Metal, glass, plastic, stone, rubber, kevlar, carbon fiber, ceramics, etc. Taper up to 59°
MICROCUT™ .0005″ – 0.5″ 0.0005″ – 0.005″ 0.009″, 0.011″,  0.0196″ 1 to 5000 Low 6-8 Days Metal, glass, plastic, stone, rubber, kevlar, laminates, carbon fiber, ceramics, etc.
* CHEMICAL ETCHING 0.005″ – 0.060″ Is +/- 10% of material thickness, .002″ min. Equal to metal thickness 1 – Infinity $350 Min. 6-8 Days Metal Only. No Burrs. Beveled Edges. Half Etch and Holes.

* Inner radius should be 100% of material thickness. Outer Radius should be 75% of material thickness.
**Dependent on geometry, volume and material: EXPEDITE options available

Why Choose Wire EDM? / /

Wire electrical discharge machining (EDM) is an efficient manufacturing method suitable for use with electrically conductive, hard materials. When conventional manufacturing methods do not work, wire EDM is often used. Wire EDM cuts complex and intricate shapes easily. Unlike some traditional manufacturing methods, wire EDM does not place any stress on the material. Wire EDM can be a one step process as no burrs are produced.

Wire EDM Quote Times / /

Use Fathom’s SmartQuote online platform to receive a quote in as little as 1 hour, usually within 24 hours. Are you ready for a wire EDM quote or to learn about another manufacturing service? Contact Fathom today to get started. Fathom’s wire EDM lead times are as follows:

  • Parts as fast as 6-8 days

Wire EDM Services Offered by Fathom / /

Does your project require wire EDM? Fathom is ready to work with you. Fathom has a single-source global network that will support your low- to high-volume projects. Using both additive and advanced technologies, Fathom manufactures high-quality products that satisfy our clients.

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 / /

Fathom’s manufacturing network includes by over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. 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 network for state-of-the-art equipment is what facilitates a rapid turnaround for our customers.

Do you need wire EDM for a more complex job? Fathom can leverage hybridized services that include wire EDM. 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 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

Wire EDM Finishing Processes / /

Wire EDM can produce a smooth, mirror-like finish, but some finishing may still be required to customize a part. Some of the common finishing processes used for wire EDM parts include:


Painting adds color, varnish, or ink to a part. Painting may include powder coating, liquid coating, or e-coating. During powder coating an electrostatically charged powder is used, which leaves a scratch-resistant and uniform coat on the metal part. Liquid coating applies wet paint to the surface of a part. When a part is e-coated, it is dipped into a bath of paint where it and the paint are electrified, resulting in the paint adhering to the part.


Transferring adds a label or design to a part. Pressure is applied to the part using a heated press, which transfers the design to the part. Transferring can also be used to print a design that will later be engraved onto the part.


Assembly is needed when a small part must be joined together with other parts to form a larger piece. During the assembly process, the workpiece is bonded together using fasteners or bonding procedures.


Drilling adds a round hole to a part. A drill press, tapping, or milling machine may be used to create a hole. Other kinds of drills may be used including spotting or peck drills.


Deburring removes raised edges or unwanted material known as burrs. Electrochemical, thermal or abrasive flow deburring may be used. 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.

Wire EDM Shops 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. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Is Fathom ITAR certified?

A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Is Fathom AS9100:2016 certified?

A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: Is Fathom NIST 800-171 certified?

A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.

Q: What is the tolerance of wire EDM?

A: The tolerance of wire EDM is +/- 0.0005”.

Q: How thin can wire EDM cut?

A: Wire EDM can cut material as thin as 0.0004”. The standard EDM wire is 0.25mm.

Q: Why is EDM so accurate?

A: Wire EDM is an accurate process when a lower power and speed are used. High precision is a possibility with wire EDM, especially when several passes are used.

How to Get Wire EDM Quotes / /

Do you need a wire EDM quote? Read to calculate costs for a project? Use Fathom’s SmartQuote application for fast quotes on any file.

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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