Stamping die plate with precision openings cut using wire EDM

Wire erosion

Manufacturing

Cylindrical Grinding

Flat grinding

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Turning

Wire erosion

Wire EDM for tooling, gauges and precision components, combined with grinding and inspection

Wire EDM (wire erosion, electrical discharge machining) is used to machine complex contours, fine slots and internal geometries where conventional machining or grinding cannot provide sufficient accuracy or access.

At Precisium, wire EDM is part of an integrated manufacturing process. Depending on the component, it is combined with milling, turning, cylindrical grinding, jig grinding and dimensional measurement. We specialise in single parts, prototypes and small series, where accuracy, repeatability and reliable results are essential.

When wire EDM is the right solution

Wire EDM is used when a component cannot be machined reliably by milling or grinding due to geometry, limited access or tight tolerances.

It is typically applied for:

very thin walls and delicate geometries with restricted tool access,
internal contours and narrow slots,
deep features or cut-throughs with a depth greater than 4× the diameter,
components with tight tolerances and functional requirements,
machining after heat treatment.

In these cases, wire EDM offers a stable and repeatable solution where other machining methods are no longer suitable.

Employee setting up a workpiece on a Sodick VL 600 Q wire EDM machine

How we perform wire EDM

Wire EDM is carried out on Sodick VL 600 Q and Agie CUT 20 machines. The focus is on reliable fixturing, properly selected cutting strategies and consistent results.

Typical capabilities:

maximum workpiece size:
- Sodick: 550 × 400 × 250 mm
- Agie: 300 × 250 × 200 mm
wire diameter: 0.3 mm
typical tolerances: ± 0.002 mm
surface finish: up to Ra 0.8
multi-cut machining: up to 4 cuts when higher accuracy is required

For components with long cutting times, machining can be performed unattended, ensuring a steady and controlled process.

If required, we also provide additional surface finishing after wire EDM, including polishing, to meet functional or surface-related requirements.

Materials

Using wire EDM, we machine:

tool steels,
stainless steels,
aluminium,
hardmetal (carbide).

Typical wire EDM applications

Wire EDM is most commonly used for:

gauges and inspection fixtures,
cutting plates,
dies,
inserts,
functional cuts, fine slots and internal contours.

These components typically require high dimensional accuracy and good repeatability, while production volume is secondary.

Collaboration and technical review

Wire EDM at Precisium is not limited to machining according to a supplied drawing.

In most projects, we:

review drawings and technical requirements,
point out critical geometries and tolerances,
support geometry optimisation and process selection,
perform dimensional inspection using suitable measuring systems (e.g. Tesa Visio).

Where beneficial, jig grinding or cylindrical grinding is used as a preparatory step prior to wire EDM to improve fixturing accuracy and the final result.

Many wire EDM projects start when standard subcontracting is no longer sufficient.

Hardened steel component manufactured with the use of wire EDM

Industries

We manufacture precision components for customers across Europe, primarily in:

automotive industry,
pharmaceutical industry,
medical technology,
mechanical engineering and toolmaking,
production of gauges and inspection systems.

Who our wire EDM services are for

We work with companies that:

require accurate and repeatable components,
manufacture technically demanding parts,
value clear technical feedback and discussion,
expect coordinated support across machining, grinding and inspection.

Our main contacts are production and manufacturing managers, with close cooperation with engineering, quality and purchasing when required.

Contact

If you have a component that requires wire EDM, or if you are unsure whether this process is suitable, you can send us your technical documentation for review.

Based on your drawings or CAD data, we:

check feasibility,
identify critical aspects,
propose a suitable manufacturing approach.

Send an inquiry or contact us for a technical discussion on info@precisium.si

Technical drawings can be provided in standard CAD formats.

Frequently Asked Questions (FAQ)

1. What types of components are best suited for wire EDM?

Wire EDM is best suited for components with complex geometries, internal contours, narrow slots, and thin walls where milling or grinding is not feasible or cannot achieve the required accuracy.

2. What tolerances can be achieved with wire EDM?

Typical achievable tolerances are up to ± 0.002 mm, depending on component geometry, material, and surface requirements.

3. What surface quality can be achieved?

The achievable surface quality depends on the number of cuts performed. Using multi-cut machining with up to four cuts, a surface finish of approximately Ra 0.8 can be achieved.
If required and if the geometry allows, the surface can also be polished after wire EDM.

4. Is wire EDM suitable for hardened materials?

Yes. Wire EDM is well suited for machining materials after heat treatment, as it does not introduce mechanical stresses that could affect part geometry.

5. What does multi-cut (multiple cut) machining mean?

Multi-cut machining means that the contour is processed in several consecutive cuts. The first cut removes most of the material, while subsequent cuts improve accuracy, geometry, and surface finish. For demanding parts, up to 4 cuts are commonly used.

6. Is additional machining required after wire EDM?

If required, yes. Depending on the function of the component, polishing or a combination with grinding can be performed to meet specific surface or dimensional requirements.

7. Which industries do you typically work with?

We support customers in:

medical technology
automotive and e-mobility
automation and machinery
pharmaceutical equipment
tooling and precision gauge manufacturing

Our services are tailored to applications where precision and reliability are critical.

8. Can you support technically demanding or non-standard components?

Yes. We are often chosen for technically demanding components that require tight tolerances, functional surfaces, or close cooperation between machining and metrology. If standard suppliers are not a good fit, we are usually able to help.

9. Do you support customers across Europe?

Yes. We work with customers across Northern, Western, Eastern, and Central Europe, supplying precision components for technically demanding applications. Our experience includes collaboration with international engineering teams and quality departments across the European Union.

10. What files are required to request a quotation?

For a technical review, PDF drawings or 3D CAD models in common formats are sufficient. Based on the documentation, manufacturability and the appropriate process are evaluated.