CAPABILITIES

Wire Cut/Wire EDM Service

Our wire cut/wire EDM services can provide high precision tolerances, as tight as ±0.0002″ for an array of industries and applications.

  • Tolerances down to ±0.0002″ (0.005mm)
  • Parts as Fast as 3 days
  • Aluminium, Steel, Copper, Polymers & More

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Our Wire EDM Service

Prolean’s Wire EDM service excels in precision manufacturing:

  • Precision: Cuts with tolerances up to 2µm(0.0001”) using thin wires.
  • Complexity: Handles intricate shapes unachievable by standard methods.
  • Expertise: Over a decade of high-quality production.
  • Microwire Capability: Uses wires as thin as 20µm(0.0008″) for exact cuts and repeatability.

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How Does Wire Cut Machining Work?

Sinker, wire, and drilling EDM

Wire EDM machining employs a thin brass wire and high voltage to cut materials without direct contact:

  • Sparks: Generates sparks to melt metal without touching the workpiece.
  • Fluid Control: Uses a special fluid to regulate charges and remove molten metal.
  • Precision Cutting: Guides the wire for intricate cuts unachievable with conventional CNC.
  • Clean Cuts: Fluid cleans the cutting area for precise, clean results.

Wire EDM Machining Materials

CNC wire cut, also known as wire EDM, is a method where a thin single-strand metal wire is used to cut a workpiece. It’s especially useful for materials that are hard to cut using other methods. Here’s a guide on the Cuttability and Tolerance of different materials when it comes to wire cutting:
Material Cuttability ToleranceRange
Tool Steel Excellent +0.005 mm
Stainless Steel Very Good +0.005 mm
Aluminum Good +0.006 mm
Conductive Plastic Fair ±0.01 mm
Conductive Ceramic Limited ±0.01 mm
Material ToleranceRange
Tool Steel +0.005 mm
Stainless Steel +0.005 mm
Aluminum +0.006 mm
Conductive Plastic ±0.01 mm
Conductive Ceramic ±0.01 mm

Metal wire cutting: Metals often have high melting points, making them a good fit for wire cutting, as the method doesn’t require significant heat.

  • Best Application: Producing intricate shapes on hardened steels, making tools, dies, and punches.
Plastic wire cutting: Certain plastics can also be wire cut, especially if they are electrically conductive. The finish is usually smooth.
  • Best Application: Manufacturing insulative components with detailed profiles or slots.

Advantages of Wire EDM

  • Production Efficiency 

Prolean’s wire-cutting process excels in productivity and delivers high-quality surfaces that usually require no further polishing, ensuring the time-efficient and standardized production of precision parts.

 

  • All Metals Capability 

Prolean’s wire-cutting service effortlessly cuts through any conductive material, regardless of hardness or brittleness. This versatility covers all metal classes, offering extensive material choices for various applications.

  • High Precision 

Prolean’s Wire EDM offers exceptional precision, achieving tolerances as fine as 10 millionths of an inch, ideal for complex components requiring strict conformity.

  • Low Distortion

Wire EDM machining avoids internal stresses and distortion by not heating, tearing, or impacting the material, ensuring the final product maintains precise dimensions and shape.

  • Very Fine Features 

Prolean’s Wire EDM excels in crafting intricate two-dimensional designs, with the wire’s flexibility allowing for precise cutting of small features without pressure, enabling detailed small geometries.

 

  • Safe Operation

Prolean’s Wire EDM operates safely at high voltages, allowing for autonomous operation that reduces costs while maintaining high safety and quality standards in production.

 

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Our Wire Cut Capabilities

Category

Details

Unique Features

Applications

Capacity & Volume

Core Service

Precision Wire EDM Machining

High precision and repeatability

Prototypes, Medium & High-Volume Production

Up to 100K+ parts

Tolerances

+/- .0001”

Extremely tight tolerances

High-precision components and tooling

Precision for both small and large production runs

Workpiece Thickness

Up to 16”

Versatile handling of various thicknesses

Parts requiring high-thickness cuts

Suitable for both thin and thick parts

Complexity

4-axis & intricate contours

Capability for complex geometries

Intricate and detailed parts

Complex parts and fine features

Cutting Method

Submerged cutting for thermal stability

Reduced thermal distortion

High-precision and high-tolerance cutting

Efficient cutting with minimal thermal effects

Automation

Auto-threading

Enhanced efficiency and reduced downtime

Continuous production runs

High-volume production capability

Prototyping

Quick turnaround for initial designs

Fast production for prototypes

Development and testing of new designs

Speedy prototyping for rapid development

High-Volume Production

Capability for large-scale manufacturing

High throughput and consistent quality

Large-scale manufacturing and continuous production

Large production runs with consistent precision

Laser Marking

High-precision part marking

Durable and clear markings

Identification and labeling of components

High-quality marking for traceability and identification

Small Hole EDM

Precision machining for small holes

Fine hole accuracy

Applications requiring small, precise holes

Ideal for intricate and small-scale applications

Category Details
Core Service Precision Wire EDM Machining
Tolerances +/- .0001”
Workpiece Thickness Up to 16”
Complexity 4-axis & intricate contours
Cutting Method Submerged cutting for thermal stability
Prototyping Quick turnaround for initial designs
High-Volume Production Capability for large-scale manufacturing
Laser Marking High-precision part marking
Small Hole EDM Precision machining for small holes

How to Order Parts?

Get a free quote from a real engineer; once we receive your design, our engineer will review it and send you a quote as fast as one hour.

Get A Quote Immediately

Upload your design or email our engineer directly and get your quotes as fast as one hour.

Start Production

Your parts will be made once your orders are confirmed. Besides, you will get real-time order updates of the production status from our order tracking system.

Receive Your Part

After all parts pass QC inspection, they will be well packed from transportation accidents. Then, your custom parts are delivered straight to your doorstep.

: We generally evaluate production and provide quotations within six hours. If you need a more urgent quote within 1 hour, please contact us directly through our official WhatsApp account or Skype for immediate communication.

Wire EDM Machining Applications

 

Aerospace Industry

Wire EDM is very useful in the aerospace industry to produce complex shapes such as turbine blades,  where high tolerances are required. It is also employed in the production of small nozzles, airframes, and intricate engine components where precision is critical and where the parts have to conform to aerospace specifications.

Medical Industry

In the medical industry, Wire EDM is used to manufacture accurate dental implants, surgical tools, and many other tools. The process is most useful when it comes to manufacturing small parts, for instance in dentistry where the parts are very small and intricate.

Manufacturing Industry

Wire EDM is widely applicable in the manufacturing of die for plastic injection molding. It guarantees the right contouring of molds which is very important in the production of large quantities of parts with standard quality. Some examples are complex molds for automobile and consumer products.

Die & Tooling Industry

Wire EDM is used to create precise components such as punches, dies, cams, gears, and custom die inserts. These parts are essential for high-accuracy stamping and forming operations, ensuring reliable performance in industries like automotive and aerospace.

Electronics Industry

Wire EDM is widely used in the electronics industry where small and accurate parts such as connectors, lead frames, and micro parts are manufactured. These parts are used in the internal circuit boards of electronics and even a slight variation in dimensions can hamper the functionality and durability of the device.

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Wire Cut Machining Gallery

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3 Ways to Ensure Perfection

Standards

Metals: ISO-2768 fH (fine)

Plastics: ISO-2768 mK (medium)

Metric threads tolerances: ISO 965-1 standard UN Threads Tolerances: ASME B1.1-2003 standard

Knurling: ISO13444:2012 standard.

Our factory is ISO 9001:2015 certificated

Inspection and Protection

Constant visual inspection conditions

Quantification of cosmetic surface quality

Process requirements

Part cleaning and Protection

Quality Inspection Report

Inspection Confirmation

Dimensional confirmation

Appearance confirmation

Quality documentation

Technology Overview

What is Wire Cut ?

The only difference between a wire cutter and a standard EDM is that a wire cutter uses copper wire electrodes of thickness varying from 0.02 to 0.3 mm. When the material to be cut approaches the copper wire electrode, the electrode’s electrical charge tends to jump over to it, creating the spark needed to cut the material. Here the workpiece should be a conductive metal so that the electrode can produce the spark.

The hardened metal and alloys, which are challenging to cut with other machining operations, are machined using the wire cut method. Because wire cutting entails applying minimal stress and little to no change in mechanical properties, it is also a successful machining technique when consistent mechanical properties are required. In addition, parts with Complex geometries, hard metal with tight tolerance requirement, excellent surface finish, and fine holes are achievable with wire cut CNC machining method.

Working Principle of Wire Cut

A low conductive liquid media (dielectric-fluid) is placed between the wire electrode and the metal to be cut. Next, the electrode wire moves close to the workpiece,

The wire becomes the cathode and the workpiece the anode when the electric supply is turned on. Due to the release of ions from the workpiece and the wire, ions tend to accelerate, increasing their kinetic energy and temperature, which leads the dielectric fluid to conduct. A spark will be produced when there is a potential difference between the electrodes once dielectric fluid starts to conduct electric current. The spark erodes the material from the pre-set position. After that, it moves away along a computer-controlled path.

The movement of the cutting wire is multidimensional, allowing the workpiece to be cut on many faces with a single setup while instructions are being sent through the computer.

The process of Wire Cut

The electrode is accurately positioned by providing coordinate instructions on the CNC machine before processing the wire cut. Since every tool used in CNC wire cutting can detect contact, they all operate using the automatic edge and center locating feature.

The wire does not touch the workpiece during the CNC wire cut process; instead, a spark is produced to carry out the operation. Cutting wire that has been electrically charged will increase the electric field as it approaches the workpiece. When it reaches electrical breakdown, the die-electric material placed between them will spark. The workpiece will then start to degrade as the spark jumps across it. The wire is continuously sent through the operation so its erosion won’t affect the cutting process.

The guide that supports the CNC wire cutting machine can move along three axes and in the x-y plane. The CNC computer controls the workpiece and guides movements.

Wire EDM FAQs

What Is Wire EDM's Cutting Method?

Wire EDM uses a thin, electrically charged wire to cut through conductive materials. The wire is continuously fed through the workpiece, generating sparks that melt and erode the material along the programmed path. This process allows for highly precise cuts without direct contact between the wire and the material.

How Accurate is Wire EDM Machining?

TWire EDM is renowned for its high precision, capable of achieving tolerances as tight as ±0.0001 inches. This high level of dimensional accuracy is ideal for producing complex parts with intricate details, ensuring that even the smallest features meet exact specifications.

Is It Possible To Wire EDM Stainless Steel?

Yes, Wire EDM can machine stainless steel effectively. The process is well-suited for cutting hard materials like stainless steel, providing clean cuts with minimal thermal impact, which helps maintain the material’s integrity with low roughness Ra.

What Is the Difference Between EDM and Wire Cut EDM?

EDM (Electrical Discharge Machining) encompasses various processes that remove material using electrical discharges. Wire Cut EDM is a specific type of EDM that uses a thin wire as the electrode to cut through the material, whereas other EDM processes might use different types of electrodes or techniques for material removal.

What Are the Disadvantages of Wire EDM?

The primary disadvantages of Wire EDM include its slower material removal rate compared to traditional machining methods, and its limitation to only conductive materials. Additionally, the process can be more expensive due to specialized equipment and consumables like the wire(electrode) itself.

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