Wire EDM / Wirecut
Wire EDM (wirecut) cuts electrically conductive material with a thin charged wire that erodes metal by sparks, producing very accurate profiles, sharp internal corners and fine details, even in fully hardened steel. It is essential for press tools, dies, punches and precision parts.
What it is
A brass wire, typically 0.1–0.3 mm diameter, is fed continuously through the part while controlled electrical sparks erode material along the programmed path under deionised water. There is no cutting force, so fragile and thin features are possible.
Because EDM works on hardened material, parts are hardened first and then cut, eliminating heat-treatment distortion. Tapers can be cut by tilting the wire.
Typical applications
- Press tool punches and die plates
- Extrusion dies and moulds
- Gear and spline profiles
- Precision slots and keyways
- Hardened components with complex outlines
Suitable materials
- Hardened tool steels (D2, D3, H13)
- Carbide
- Stainless steel
- Titanium and alloys
- Copper and brass
Points to consider
- Only conductive materials can be cut.
- Internal profiles need a start hole drilled before cutting.
- Multiple skim passes improve accuracy and finish but add time.
- EDM leaves a thin recast layer; for fatigue-critical parts discuss post-processing.
Frequently asked questions
Can wire EDM cut hardened steel?
Yes. That is one of its main uses: parts are hardened first, then wire cut without distortion.
How accurate is wirecut?
Typically around ±0.005–0.01 mm, making it suitable for press tools, dies and precision parts.
Can wire EDM make sharp internal corners?
Nearly. The minimum internal radius is about half the wire diameter plus the spark gap, around 0.1 mm.