Wire EDM Tolerances
Wire EDM machining makes precise and accurate cuts in a variety of metals. It’s ideal for creating complex designs that may be challenging to fabricate using other cutting techniques. The hardness of the material has no effect on the cutting speed of this technology, which means it can cut a stack of metal plates at the same time as a single workpiece.
Wire EDM Tolerances for Precision Parts
Wire EDM tolerances are superior to other types of metal cutting: conductive materials can be rough cut using wire EDM to a tolerance of .002 inch. With trim passes, tolerance can be increased to .0002 inch. This level of accuracy is possible because wire EDM cutting doesn’t make physical contact with the metal when cutting it. It uses a thin electrode wire that carries a high-voltage charge. The resulting spark melts the material adjacent to the wire, resulting in a very precise cut.
How Wire EDM Tolerances Differ from Other Cutting Processes
Here’s how wire EDM tolerances compare to other cutting methods. As you can see, it can make much finer cuts than laser, water jet or Microcut (micro water jet cutting).
| Material Thickness | Tolerance | Kerf | Part Volume | Set Up Cost | Lead Time ** | Notes | |
|---|---|---|---|---|---|---|---|
| WIRE EDM | 0.001″ – 15.0″ | 0.0001″ | 0.005″ | 1-High Volume | Low | 6-8 days | Conductive Metals |
| 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.
Fathom Wire EDM Tolerances & Specifications
Wire EDM cutting from Fathom provides higher cutting accuracies and tighter tolerances than other metal cutting processes:
- 5-Axis
- Wire diameter: 0.004~0.012 in.
- Tolerance: 0.0001 in.
- Maximum taper angle: 30º @ 8 in. material thickness
- Position Accuracy: .0001 in. (.003mm)
- Feature and Contour Accuracy: +/- 0.0001 in.
- Kerf Width: 0.006-0.014 in.
- Maximum Workpiece Dimensions: 27 x 40 in.
- Maximum Workpiece Thickness (may be stacked sheets): 15 in. thick
Wire EDM Materials List
Wire EDM can only be used with conductive metals. Fathom offers many materials for processing with wire EDM, including:
- Copper
- Carbide
- Tungsten
- Bronze
- Carbon steel
- Inconel
- Stainless steel
- Hastalloy
- Kovar
- Titanium
- Carbon graphite
- High alloy steel
Tips for Designing Parts to Achieve Tight Wire EDM Tolerances
Keep these tips in mind when designing your parts for proper EDM machining tolerances:
- Remember the kerf width when designing your parts. Otherwise, certain features may end up being under-sized.
- Consider the wire diameter when sizing internal corners. Making them larger than necessary to help ensure clean cuts.
- If your design includes taper angles, you ought to check with your manufacturing partner to determine if its wire EDM machines can handle them. Fathom’s maximum taper angle is 30º at an 8 in. material thickness.
What Industries Require Tight EDM Machining Tolerances?
Industries that require complex, tight-tolerance parts – where wire EDM cutting is the preferred manufacturing solution – include:
- Aerospace
- Defense
- Automotive
- Electronics
- Solar
- Injection molding tools
In many cases, customers in these industries require prototype or low-volume, highly-customized parts.
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 // 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.
Transfers // 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 // 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 // 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 // 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.
Fathom offers comprehensive post-processing options for parts produced with wire EDM cutting. Contact our wire EDM experts to learn more and discuss your metal cutting and forming needs.
Why Choose Wire EDM Cutting?
Minimal Post-Processing Required // Wire EDM machining makes precise and accurate cuts, reducing the need for finishing and secondary processes. This makes it a very cost-effective cutting method. The wire EDM cutting process doesn’t produce burrs like other cutting methods.
Perfect for Parts With Complex Geometries // Wire EDM machining is ideal for creating complex designs that may be challenging to fabricate using other cutting techniques or CNC machining. It can also cut sharp corners with minimal radii.
Excellent Edge-Cut Quality // Wire EDM provides a clean vertical cut compared to water jet cutting, which tends to become less accurate toward the bottom of the cut, as the water jet begins to dissipate. EDM machining tolerances are the finest of any cutting method.
Wide Variety of Materials // Wire EDM cutting can cut both tough and brittle metals without damaging them.
Cost-Effective // Metal plates can be stacked to cut multiple workpieces in a single pass. This makes wire EDM cutting very cost-effective compared to other cutting methods.
Fathom’s Locations
for Wire EDM
Fathom’s nationwide network has several locations across the U.S. that offer wire EDM services:
Arizona //
444 W. 21st St. Ste. 101
Tempe, AZ 85282
Illinois //
1207 Adams Drive
McHenry, IL 60051
1401 Brummel Avenue
Elk Grove, IL 60007
Texas //
1513 Sam Bass Rd.
Round Rock, TX 78660
New York //
1920 Slaterville Rd.
Ithaca, NY 14850
Choose Fathom For Your Tight Tolerance Wire EDM Needs
We’ll help you achieve the precise dimensions that your parts require
When you need tight tolerance wire EDM tolerance cutting, count on Fathom. Our Tempe location is one of the most experienced shops for wire EDM cutting in the country. It’s been helping customers for multiple industries solve their precision metal cutting challenges for over two decades.
Do you have a complex metal part design that’s challenging to fabricate? Tight tolerance wire EDM cutting may be the solution.
Let’s get started on your next project!
