Wire Cut Service
Our wire cut 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
Why Choose Our Wire Cut Service
Do you need any small intricate shapes and patterns? EDM wire-cut process is fully capable of fulfilling your requirements. It can create small and accurate holes, punches, Extrusion dies, Miniature parts, needles, turbine blades, and many more. Prolean is committed to ensuring that customers are satisfied. Our Specific series of Advanced EDM wire cut machines and experienced engineers are ready to meet your needs.
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 quotation as fast as one hour.
Get One Hour Quote
Upload your design or send an email directly to our engineer and get your quotes within as fast as one hour
Your parts will get made once your orders confirmed, besides, your will get real-time updated of the production status from our order tracking system
Receive Your Custom Part
After all parts pass qc inspection, they will be well packed from any transportation accidents. Then, your custom parts are delivered straight to your doorstep
CNC Machining Materials Options
AluminumAluminum is a superior metal in terms of strength-to-weight ratio. It offers High Machinability, ductility, and thermal & electrical conductivity. Parts with aluminium also become highly resistant to corrosion.
BrassGolden shiny color, low friction, excellent Machinability, and high electrical & thermal conductivity. Brass can be easily machined and the best choice for low-friction applications.
CopperIt offers good strength, hardness, and excellent corrosion resistance with superior heat and thermal conductivity. It also has a very appealing aesthetic.
Titanium40% more strength-to-weight ratio than steel, Excellent corrosion resistance, low thermal expansion, and biologically inert. These properties make it perfect for automotive, aerospace, and medical applications.
AlloysGrade 1 Titanium
Grade 2 Titanium
Grade 5 Titanium（TC4, Ti6Al4v)
Alloy SteelHigh mechanical strength, toughness, resistance to wear and fatigue, and sturdiness. In addition to carbon, other alloying elements can be added depending on the needed mechanical and physical qualities.
AlloysAlloy Steel 4130
Alloy Steel 4340
Steel (4140 Alloy)
Steel (1018 Low Carbon)
Tool Steel (A2)
Zinc-Galvanized Low-Carbon Steel
Carbon Steel (1045)
Stainless SteelHigh mechanical strength, Thermal, Wear, and Corrosion resistance. Stainless steel is low-cost and can be machined easily. Parts made from Stainless steel are durable and do not lose that strength over time.
AlloysStainless Steel 201
Stainless Steel 301
Stainless Steel 303
Stainless Steel (304L)
Stainless Steel (316L)
Stainless Steel (410)
Stainless Steel (420)
Stainless Steel (440C)
Stainless Steel (17-4 PH)
Cast ironIt offers three to five time’s higher compression strength than steel. Low notch sensitivity, Good Resistance to deformation, excellent anti-vibration, and consistent mechanical properties
- Garolite G-10
- Polyethylene (PE)
- PPSU（Polyphenylene sulfone resins）
- PPS (Polyphenylene)
- PTFE (Teflon）
- polyetherimide (PEI)
- PMMA (Acrylic)
ABSExcellent strength, extraordinary impact, and abrasion resistance with chemical inertness. ABS can be machined easily and is very easy to paint and glue.
AcrylicAcrylic is a lightweight, rigid thermoplastic with optical clarity. It is one of the superior alternatives to glass, offering excellent weather and chemical stability.
DelrinHigh tensile strength, excellent Machinability, Stiffness, wear resistance, creep resistance, and low friction. Overall, Delrin is the ideal replacement for metal.
SubtypesDelrin (30% Glass-Filled)
Garolite G-10High strength to weigh ratio, fire resistive, low thermal expansion coefficient, and water absorption coefficient are entirely free from corrosion risk. Garolite is perfect for insulating parts and electric circuit boards.
FR4FR-4 is a manufacturing material with strength almost equal to steel and lightweight. It is a perfect fit for making parts for the electrical marine industry since it is flame retardant, has a negligible water absorption coefficient, and is machinable.
Polyethylene (PE)Polyethylene is known for its malleable properties. It offers a high strength-to-weight ratio, impact strength, chemical inertness, temperature, and weather resistance.
NylonMechanical properties include high resilience, tensile strength, and fatigue resistance. Nylon is a flexible manufacturing material that is highly resistant to abrasion, heat, chemicals, water, and oils.
SubtypesNylon (30% Glass-Filled)
PEEKA versatile engineering material with high mechanical strength. It provides excellent thermal and chemical resistance. Parts from PEEKS are durable and can be operated at an extensive range of temperatures (up to 2600).
SubtypesPEEK (30% Glass-Filled)
Polycarbonate（PC）Exceptional mechanical properties, including impact strength, toughness, Stiffness, and creep resistance. Because of its transparent nature, Polycarbonate (PC) is a lightweight alternative to glass.
Polypropylene(PP)A low-cost material with good Stiffness, impact resistance, and chemical stability. PP also offers excellent wear resistance and elasticity.
PPSU（Polyphenylene sulfone resins）PPSU is used in various sectors because of its lightweight, high toughness, great impact resistance, high heat resistance, chemical stability, transparent color, and wide operating temperature range
PPS (Polyphenylene)The unique combination of Physical, mechanical, and chemical properties. Excellent strength, rigidity, fatigue endurance, creep resistance, chemical inertness, and a wide range of working temperatures for the fabricated parts make it a perfect choice for electrical applications with high operating temperatures.
PTFE (Teflon）High chemical inertness, thermal stability, electrical insulation, and corrosion resistance. Teflon is a low-friction substance that is perfect for making non-sticky and sliding parts for various industries.
polyetherimide (PEI)Semi-transparent, high strength, rigidity, thermal stability, chemical inertness, and dimensional stability. Parts made from PEI can work for an extended period without stress cracking.
PMMA (Acrylic)Transparent, lightweight, strong mechanical strength, hardness, thermal stability, and chemical inertness. Transparent nature makes it an excellent alternative to glass.
PVCExcellent Stiffness, flame resistance, weather resistance, dimensional stability, and chemical inertness. PVC is appropriate for pipelines, medical devices, outdoor appliances, and electrical insulation.
CNC Machining Material Guide
As the machined or deburring
The machined or deburring finish is the standard finish where unwanted attach chips are removed with deburring tools, and sharp edges are chamfered to smooth the surface (3.2 μm).
Bead blasting produces a matte texture, removing all the marks of machining tools. It applies to ABS, Aluminum, Brass, Stainless Steel, and Steel parts.
Anodizing involves adding an aluminum oxide coating to aluminum and its alloys. The layers, which come in various colors, increase strength and shield the surface from corrosion.
Powder coating is the electrostatically applying of dry powder to the surface. It produces a thin layer providing excellent resistance to wear, corrosion, and abrasion.
Physical rubbing of a metal surface to create a shiny surface is called a polishing surface finish. It increases the reflectivity and does not affect the dimensional stability of parts.
Brushing is achieved by applying an abrasive brush to the metal surface, which produces a unidirectional satin finish. And it is not recommended for highly corrosive materials.
Smooth machining is done by controlling the machining process, such as feed rate & cutting speed. It minimizes the tool marks and risk of corrosion.
Black oxide finish reduces surface reflectivity and offers mild corrosion protection. It involves adding a thin layer of magnetite to the surface.
Electro-less Nickel Plating
A thin layer of Nickel is created on the surface from a nickel-containing solution without electrolysis. Electro-less nickel plating provides a shiny appearance, excellent hardness, abrasive, wear, and corrosion-resistance to the substrate material.
Provides excellent corrosion resistance property to the aluminum parts with greenish-gold color. It is the low-cost and quick surface finishing approach.
Electroplating increases the hardness of the steel &aluminum parts. It offers excellent corrosion, wears, and abrasion resistance.
Make the parts super resistive to corrosion. It enhances mechanical strength, hardness, wear resistance, lubricity, and ductility. Nickel plating is applicable in different materials, including Steel, aluminum, copper, and brass.
Enhance the appearance and functionality of the parts. After Passivation, parts of Steel and its alloys become super resistive from corrosion.
Yellow Chromate conversion coating
A shiny appearance with goldish color provides excellent corrosion resistance. It is applied on the surface of aluminum, magnesium, and their alloys. A layer of chromate also enhances the conductivity of parts
PTFE (Teflon) Coating
The Teflon layer on the parts offers excellent corrosion resistance, water resistance, and non-stickiness with a non-reactive surface.
The higher-precision machines produce delicate machining surfaces by utilizing sharper tools and regulating feed rate and cutting speed. Surface roughness up to Ra 0.8 μm can be maintained with smooth machining.
Provides excellent corrosion, wear, and abrasion resistance. Laser Cladding is also effective for treating minor surface imperfections such as cavities, tiny cracks, and rust damage.
Provides a random, non-linear texture with a shiny, high gloss finish. However, it might be unable to create sharp corners and pockets
3 Ways to Ensure Perfection
For metals, the standard is ISO-2768 fH (fine)
For plastics, the standard is 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
Visual inspection and Protection
Constant visual inspection conditions
Quantification of cosmetic surface quality
Part cleaning and Protection
Quality Inspection Report
Design Guidelines-CNC Machining and Sheet Metal
You’ll find it all here, from the material, selection, and standard tolerances to design advice for each operation we provide, including sheet metal bending, Laser-cutting, water-jet cutting, and surface finishing options.
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.
See why customers dig us
What are standard tolerances I can get from Prolean's?
We offer a total machining tolerance of 1/100 to 2/100 mm for wire cut operations. Using better temperature control, we may provide tolerance of as near as 5/1000 mm for sensitive products.
What types of wire cut machines do Prolean's have?
We can create precise structures for you using high-speed KNUTH wire EDM machines, which can work with steel, brass, aluminum, hard alloys, and even steel that has been hardened or tempered. We can handle workpieces up to 800 kg and 1200 mm in diameter.
What types of shapes can be produced by a wire cut approach?
With the help of the CNC wire cut process, nearly all conductive metals and alloys with a thickness of no more than 300mm can be cut accurately. Steel, titanium, aluminum, brass, and even hardened alloys are on the list of materials. Applications include machine parts, brand logos, small prototypes with precise tolerances, stamping dies, minor hole drilling, and blanking punches.
What is the difference between traditional EDM and wire cut approach?
The primary difference between wire cut and EDM is that wire cut uses brass or copper wire as the electrode, whereas wire structure is not used in EDM. Compared to functionality, the wire-cut technique can produce smaller angles and more complicated patterns.
What are the advantages of the wire cut method?
Three primary benefits include the ability to achieve great precision and accuracy. Next, wire Cutting takes less force because there is no direct contact between the tool and the workpiece. Finally, while other machining methods have issues with the hardness and toughness of the work material, this one does not.
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