Wire-Cut EDM Machining

Precision Wire-Cut EDM Machining

Slinar specializes in manufacturing precision jigs, fixtures, and tooling components using Wire EDM and Sinker EDM. We machine hardened steel and carbide to extreme tolerances, producing critical parts like locating pins, bushing plates, and custom inspection fixtures that ensure manufacturing accuracy.

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Wire EDM Machining Services

Our high-precision EDM wire cutting services deliver micron-level accuracy for the most demanding applications. Equipped with state-of-the-art Mitsubishi machines, we specialize in complex geometries, tight tolerances, and superior surface finishes.

✔ Advanced Technology – Imported Mitsubishi CNC EDM systems ensure repeatable ±0.005mm precision
✔ Complex Geometries – Expertly handle multi-axis contours, sharp corners, and thin-walled features
✔ Material Versatility – From hardened tool steels to exotic alloys, we cut it all
✔ Surface Finish Excellence – Achieve mirror-like finishes down to Ra 0.2μm

WEDM Material Guide

Material Category	Specific Materials	Conductivity	Machining Advantages	Typical Applications
Tool Steels	H13, SKD11, D2	Excellent	Direct machining of hardened state (HRC60+)	Mold inserts (plastic/die casting)
Carbides	YG8, YT15 (Tungsten-Cobalt)	Excellent	No edge chipping, ±0.005mm accuracy	Cutting tools/wear parts
Stainless Steels	304, 316L, 17-4PH	Excellent	Mirror finish (Ra≤0.2μm)	Medical implants/gears
Titanium Alloys	TC4 (GR5), TA2	Good	Avoids α-phase embrittlement	Aerospace fasteners/implants
Superalloys	Inconel 718, Hastelloy X	Moderate	Solves work hardening challenges	Turbine blades/combustors
Aluminum Alloys	6061, 7075	Excellent	No deformation in thin-wall parts	Optical mounts/heat sinks
Copper/Alloys	Pure Copper, BeCu (C17200)	Outstanding	Ultra-fine contour machining	Electrodes/RF connectors
Refractory Metals	Molybdenum (Mo), Tungsten (W)	Good	Micro-hole drilling (≥0.05mm)	Semiconductor fixtures/nozzles
Metal Matrix Composites	AlSiC	Moderate	Isotropic machining	Electronic substrates
Sintered Metals	PM parts (Fe-Cu system)	Moderate	Final precision finishing	Self-lubricating bearings
Conductive Ceramics	Doped ZrO₂ (e.g., ZrO₂+Ni)	Weak	Special parameter processing	Medical probe tips

Precision WEDM Components for Jigs & Fixtures

This gallery features critical components machined from hardened steel and carbide using Wire and Sinker EDM. See examples of precision locating pins, bushing plates, and custom tooling elements that ensure manufacturing accuracy and repeatability.

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WEDM machining tolerances

We follow ISO 2768 standards for CNC machining.

Limits for nominal size	Plastics (ISO 2768- m)	Metals (ISO 2768- f)
0.5mm* to 3mm	±0.1mm	±0.05mm
Over 3mm to 6mm	±0.1mm	±0.05mm
Over 6mm to 30mm	±0.2mm	±0.1mm
Over 30mm to 120mm	±0.3mm	±0.15mm
Over 120mm to 400mm	±0.5mm	±0.2mm
Over 400mm to 1000mm	±0.8mm	±0.3mm
Over 1000mm to 2000mm	±1.2mm	±0.5mm
Over 2000mm to 4000mm	±2mm
*Please clearly indicate tolerances for nominal sizes below 0.5mm on your technical drawing.

WEDM processing

Non-Reversible Material Effects in WEDM (Key Difference from CNC Machining)

Feature	Technical Advantage	Geometric Tolerance Relevance
Non-contact machining	Zero mechanical cutting force, eliminating material deformation	Maintains ±0.005mm tolerance even for thin walls (<0.1mm)
Hardness-independent	Processes hardened steels (HRC 60+), carbides, and other difficult-to-machine materials	Post-heat treatment machining avoids secondary distortion
Micro-feature capability	Achieves ultra-fine features (e.g., 0.02mm micro-holes/slots, fuel injector nozzles)	IT5-grade precision for gear/mold profiles (e.g., involute curves)
Omnidirectional cutting	Multi-axis tilting (e.g., 5-axis) enables deep cavities/undercuts	≤0.01mm positional accuracy for complex surfaces

WEDM's Precision Edge Over Laser Cutting

Minimum Internal Corner Accuracy

WEDM achieves R0.03mm vs Laser R0.1mm

Perpendicularity Control

WEDM 0.005mm/100mm vs Laser 0.02mm/100mm

Heat-Affected Zone (HAZ)

WEDM: None vs Laser: 20-50μm hardened layer

Specialized WEDM Workshop for Tooling & Fixtures

Our EDM department is dedicated to machining the unforgiving materials and complex geometries found in high-performance jigs and fixtures. We achieve unparalleled accuracy in hardened steel and carbide, where traditional machining methods fail.

Integrated CNC Machining Workshop

Precision Wire EDM Machining

CMM workshop

Surface finishing workshop

Quality Inspection Department

Grinding machine center

Wire-Cut EDM Machining for Jigs & Fixtures

What makes EDM better than milling for hardened tooling components?
A: Unlike milling cutters that wear down and struggle with hardened steel (above 45 HRC) and carbide, EDM is a non-contact process that uses electrical discharges to erode material. This allows us to machine these ultra-hard materials with exceptional precision and create sharp, burr-free edges without inducing stress or micro-cracks, which is critical for the longevity of jigs and fixtures.

What's the difference between Wire EDM and Sinker EDM for my project?

The choice depends on the feature:

Wire EDM is ideal for through-cutting complex 2D profiles, intricate holes, and sharp internal corners in plates and blocks. Think of it for creating bushing plates, blanking dies, or ejector pin holes.

Sinker EDM (or Ram EDM) is used to form cavities, 3D shapes, and negative features. It's perfect for machining locating pin heads, nesting features, or custom electrode shapes into a hardened tooling block.

What materials do you most commonly machine with EDM?

We primarily work with materials that are difficult or impossible to machine with traditional methods once hardened. This includes:

Tool Steels: D2, A2, O1, M2 (fully hardened)
Carbide: Tungsten carbide for extreme wear resistance.
Stainless Steels: 400 series, 17-4 PH for corrosive environments.
Exotic Alloys: Inconel, Hastelloy for specialized applications.

What level of precision and surface finish can I expect?

Our standard Wire EDM process can consistently hold tolerances of ±0.005mm (±0.0002") and achieve surface finishes down to Ra 0.4 μm (16 μin). Sinker EDM can achieve similar tolerances, with finishes capable of reaching Ra 0.2 μm (8 μin) or better for fine details. Specifics depend on the material and feature size.

Can you machine pre-hardened parts without affecting the surrounding material?

Yes, this is a key advantage of EDM. Since it's a thermal process and not a mechanical one, it does not affect the metallurgical properties of the material outside the immediate spark area. This allows us to add precise features or make modifications to finished, heat-treated components without risking distortion or softening.

What information do you need to provide a quote for a custom EDM part?

To provide an accurate quote and DFM analysis, please provide:
3D CAD Model (STEP, IGS, X_T preferred) and 2D Drawings with all critical dimensions and tolerances (GD&T is extremely helpful).
Material Specification (type and hardness).
Quantity and any required surface finish callouts.
The part's function (e.g., "locating pin for welding fixture") helps us ensure the best process is selected.

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