Ultra-Precision
Wire EDM
Services
For intricate shapes, sharp internal corners, and superior finishes in any conductive material, regardless of hardness.
Micron-Level Tolerances| Hardened Materials | Complex Geometries | Burr-Free Finish
What is Wire EDM?
Cutting with Sparks, Not Force
Wire EDM is a non-contact thermal machining process that uses a thin, electrically charged traveling wire as an electrode to cut intricate shapes through conductive materials. The wire never touches the workpiece; instead, a controlled electrical discharge (spark) erodes the material, allowing for stress-free cutting of complex parts and features that are impossible to achieve with traditional machining methods.
Our Core Wire EDM
Capabilities
Micro Wire EDM
Utilizing wires as thin as 0.02mm, we can create micro-features, miniature parts, and incredibly fine details for medical and electronic applications.
Taper & Angle Cutting
Our advanced 4 and 5-axis machines can perform complex taper cuts up to 45°, ideal for creating draft angles, relief features, and mold components.
4/5-Axis Wire EDM
We machine complex 3D shapes, tapered contours, and features with independent top and bottom profiles, enabling highly complex part geometries.
Tool, Die & Mold Components
We are experts in manufacturing high-precision punches, dies, inserts, and ejector pins from hardened tool steels with exceptional accuracy.
Submerged Cutting
Most of our work is performed submerged in deionized water, which provides stable temperatures, efficient flushing, and superior surface finishes.
Internal Shape Cutting
Perfect for cutting intricate internal splines, keyways, and complex shapes after a small start-hole has been drilled.
Why Choose RAPMAF
Manufacturing for Wire EDM
Unmatched Precision
We consistently achieve tolerances as tight as ±0.002 mm (±2 microns), ensuring your most critical components meet and exceed specifications.
No Mechanical Stress
As a non-contact process, Wire EDM imparts no mechanical stress on the workpiece, eliminating distortion and making it safe for delicate or thin-walled parts.
Hard Material Specialist
The process is indifferent to material hardness. We can cut hardened tool steels, carbide, titanium, and exotic alloys with the same ease as soft aluminum.
Sharp Internal Corners
Achieve sharp, precise internal corners down to the radius of the cutting wire, a feat impossible with traditional milling.
Through multiple “skim cuts,” we can achieve mirror-like surface finishes as fine as 0.1 μm Ra, often eliminating the need for secondary polishing.
Expert DFM Support
Our engineers help optimize your design for the Wire EDM process, providing feedback on start-hole placement, feature feasibility, and tolerance expectations.
Technical Specifications
| Feature | Specification |
|---|---|
|
Max. Workpiece Size |
1000 x 600 x 400 mm |
|
Best Achievable Tolerance |
±0.002 mm (2 µm) |
|
Wire Diameters |
0.02 mm to 0.3 mm |
|
Best Surface Finish (Ra) |
Up to 0.1 µm |
|
Max. Taper Angle |
±45° over 100 mm thickness |
|
Positional Accuracy |
±0.001 mm |
Our Wire EDM
Workflow
Step 1
Programming & Simulation
Our engineers use advanced CAD/CAM software to program the precise wire path and simulate the entire cutting process to prevent errors.
Step 2
Setup & Fixturing
The workpiece is precisely located and securely fixtured on the machine table. If required, a start-hole is drilled for internal features.
Step 3
Automated Wire Cutting
The machine begins the automated cutting cycle, often starting with a rough cut followed by a series of fine “skim cuts” to achieve the final dimension and finish.
Step 4
Metrology & Inspection
Upon completion, every part is thoroughly inspected using CMM, VMM, or optical comparators to verify all dimensions and features meet your specifications.
Alloys We Cast
Tool Steels
Description
(A2, D2, S7, M2, H13) – For high-strength molds, dies, and punches.
Stainless Steel
Description
(304, 316, 17-4 PH) – For medical, food-grade, and corrosion-resistant parts.
Aluminum
Description
(6061, 7075) – For lightweight aerospace and automotive components.
Titanium
Description
For high-strength, lightweight medical and aerospace parts.
Carbide
Description
For ultra-hard cutting tools and wear-resistant components.
Copper & Brass
Description
For electrical contacts, electrodes, and decorative parts.
Inconel & Exotic Alloys
Description
For high-temperature and harsh-environment applications.
Graphite
Description
For creating sinker EDM electrodes.
If your project requires a specific resin not listed here, our engineering team can source and process it to meet your exact specifications.
Precision & Finish Options
Rough Cut (1 Pass)
The fastest and most economical option. Ideal for non-critical features or pre-machining before heat treat.
General Finish (2-3 Passes)
Our most popular option, offering a great balance of good surface finish, high accuracy, and cost-effectiveness.
Fine Finish (4-5 Passes)
For applications requiring very high dimensional accuracy and near-mirror surface finishes, like high-end mold cavities.
Ultra-Fine Finish (6+ Passes)
Reserved for the most demanding applications in metrology, medical, and scientific instruments, achieving the absolute best finish and precision possible.
Industries We Serve
We assemble complex robotic arms,end-effectors, and control boxes,integrating motors,sensors, and wiring
We build diagnostic equipment and lab instruments in a controlled environment,adhering to strict quality and documentation standards.
We provide final assembly for high-end audio equipment, smart home devices,and other consumer products ready for market.
We assemble ruggedized enclosures，mil-spec connectors,and mission-critical hardware with full traceability and documentation.
Showcase of Our Wire EDM Parts
Explore a selection of parts we have produced, highlighting our ability to achieve extreme precision and complex geometries in the world’s toughest materials.
Precision Guaranteed in Every Part
- Material & Program Verification
We verify all incoming material certifications and use simulation software to confirm the cutting program’s accuracy before a single spark is made.
- In-Process Control
Our machines constantly monitor and adjust for wire tension, water conductivity, and temperature to maintain stable cutting conditions and ensure consistency.
- Final Metrology Inspection
Every critical dimension is verified using state-of-the-art CMM, high-resolution VMM, and surface profilometers. A full inspection report is available upon request.
Related Articles &
Insights
Inquiry & FAQs
We’ve answered some of the most common questions our customers ask about our high-precision laser cutting services.
We guarantee that all the files and pictures you upload will be kept confidential and no customer personal information will be disclosed.
Wire EDM fundamentally relies on electrical discharge, so it can only be used to machine materials that conduct electricity, such as metals and graphite.
For internal features, a small “start-hole” must first be drilled through the workpiece. The EDM wire is then threaded through this hole to begin the internal cut.
Wire EDM uses a thin, traveling wire to cut a 2D path through a part’s thickness, like a bandsaw. Sinker EDM uses a custom-shaped electrode to “sink” into the material, creating a 3D cavity, like a stamp.
It can create extremely sharp corners, but not perfectly sharp (a zero radius). The minimum internal corner radius is limited by the radius of the cutting wire plus the spark gap.
The recast layer is a very thin, hard layer of melted and resolidified material left on the surface after a cut. Our fine-finish skim cuts are designed to minimize or completely remove this layer.
Since Wire EDM is stress-free, it can cut parts after they have been hardened to their final state. This eliminates the risk of distortion that can occur if a soft part is machined and then heat-treated.
The cost depends on the cutting time. While it can be slower than traditional machining for simple parts, it is often the most cost-effective or only method for complex geometries, hard materials, and high-precision requirements.
The deionized water acts as a dielectric fluid. It cools the workpiece, flushes away eroded particles (swarf), and prevents the spark from becoming an uncontrolled arc, ensuring a stable cutting process.
We can cut materials up to 400 mm (approx. 15.7 inches) thick. However, the achievable accuracy and taper angle may decrease as the thickness increases.
For micro-machining applications, we can use wires as thin as 0.02 mm (20 microns). Our standard wire diameters range from 0.1 mm to 0.3 mm.
Yes, but it is microscopically small. The rapid cooling from the dielectric fluid means the HAZ is negligible and typically has no impact on the part’s structural integrity.
Quotes are primarily based on the machine time required. This is calculated from the total length of the cut, the material’s thickness, and the number of skim passes needed to achieve the required finish and accuracy.
Yes. Our 4 and 5-axis machines have independent U/V heads that can tilt the wire, allowing us to cut precise angles and tapers.
We need a 2D (DXF) or 3D (STEP) file of your part, the material type, the total thickness to be cut, the required quantity, and your specified tolerances and surface finish requirements.
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