Wire EDM Services — Accuracy, Thickness & When to Use

Wire EDM cuts by running a thin charged wire through the part and eroding metal with electrical sparks in a dielectric bath. Because nothing touches the part mechanically, it cuts hardened steel as easily as soft steel and holds features that would break a milling cutter — which makes it the go-to for dies, punches and precision profiles.

Capabilities at a glance

Parameter	Range
Positional accuracy	±0.005 mm
Min internal corner	≈ 0.13 mm (0.25 mm wire)
Max cut thickness	≈ 300 mm
Surface finish	down to Ra 0.4 µm (multi-pass)
Materials	Hardened & tool steel, carbide, titanium, aluminum, copper — conductive only
Taper cutting	Yes, angled walls within machine limits

Where EDM earns its keep

Stamping dies and punches in hardened tool steel that cannot be milled after heat treatment.
Sharp internal corners and narrow slots beyond any end mill.
Thin, delicate or stacked parts that would deflect under cutting force.

Soft prismatic parts are cheaper to mill; rotational parts are turned. Check the tolerance reference to decide when EDM precision is actually needed.

Frequently asked questions

When should I use wire EDM instead of milling?

Use EDM when the material is hardened, the internal corners are too sharp for a cutter, or the part is too thin or delicate to take tool pressure. EDM cuts by electrical erosion, so there is no cutting force on the part.

What accuracy does wire EDM hold?

Positional accuracy is around ±0.005 mm with a very fine surface. Internal corner radius is limited only by the wire diameter — typically 0.25 mm wire gives a 0.13 mm corner.

What thickness can you cut?

We cut up to roughly 300 mm thick on standard wire machines. Tall stacks of the same profile can be cut together to lower per-part cost.

Does the material need to be conductive?

Yes — wire EDM only cuts electrically conductive materials (steels, tool steel, carbide, titanium, aluminum, copper). It cannot cut plastics or ceramics.

Wire EDM