Wire, Sinker And Large Part EDM Services

Electrical Discharge Machining (EDM) is an advanced machining process that relies on the precise application of electrical sparks to produce a desired workpiece shape or finish.

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Wire EDM Services
Sinker EDM Services
Fast Hole EDM Services
Large Part EDM Services
CNC Machining Services

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Endless Options

Choose from millions of possible combinations of materials, finishes, tolerances, markings, and certifications for your order.

Easy to Use

Get your parts delivered right to your door without the hassle of sourcing, project management, logistics, or shipping.

The Wire EDM Machining Experts

SyncFab wire EDM machining service is a great choice for high quality, ISO 9001:2015 certified parts.

Machining Capabilities

Wire EDM Services

SyncFab offers precision 3, 4 and 5-axis wire EDM services for Kovar®, Inconel®, iron, copper, stainless steel, carbon steel, titanium, aluminum, tantalum and nickel alloys.

Laser Cutting

SyncFab provides a readily-available network of U.S.-based Laser Cutting suppliers to fulfill orders quickly, economically, and to the highest quality.

CNC Shearing

SyncFab vets CNC shearing suppliers to ensure shops have the capacity, qualifications, certifications, and experience to deliver.

CNC Punch Press

SyncFab vets CNC Punch Press suppliers to ensure shops have the capacity, qualifications, certifications, and experience to deliver.

CNC Milling

CNC milling is used to produce many parts and geometry types. With tight tolerances and high accuracy, CNC milling is a 3-axis rotating tool.

Electron Beam Welding

SyncFab vets Electron Beam Welding suppliers to ensure shops have the capacity, qualifications, certifications, and experience to deliver.

CNC Materials

CNC Finishes

Applications for Wire EDM Machining Services

OEMs can slash procurement time and costs for precision parts with a supplier network secured by blockchain for anti-counterfeit, recalls and more.

Tooling Parts

Because CNC can be applied
to virtually any material, it is
perfect for rapid tooling, i.e.,
creating fixtures or molds.

NPI Prototyping Parts

The range of materials available,
low cost per unit, and speed of
production makes a great
option for prototyping.

Production Parts

High-quality finish, vast material
options and precise tolerances
have made a favorable
technology for end-use parts.

Wire EDM Machining Services for Industrial Applications

Manufacturers producing complex, critical, and precision products rely on Wire EDM Machining Services capabilities to deliver the parts needed at the highest quality, greatest speed, and best comparable price.

Working with experienced and certified Wire EDM Machining Services shops provides a wide range of manufacturers, in a variety of industries, with the high-quality components required.

What is EDM Machining?

Electrical discharge machining creates an electrical current between the conductive workpiece and an electrically charged rod or wire composed of a brass, copper, graphite, or tungsten alloy. The spark created by the electrical current slowly erodes the material while waste material gets washed away by non-conductive fluid, such as deionized water or oil.

With EDM, manufacturers can create extremely fine and accurate details with highly polished finishes. This makes EDM ideal for the fabrication of precision dies and manufacturing molds. Since dies and molds must be able to withstand repeated use, high temperatures, and extreme pressure, they are typically manufactured from tool steel or other very hard materials. These materials are difficult to cut or machine using traditional machining methods.

Precision EDM Machining & Engineering at the Highest Level

EDM Machining Process

The EDM machining process is relatively straightforward. The conductive substrate material, or anode, is situated with an electrically conductive tool, or cathode, to create an electric current between them. It is important to note that these electrodes never actually touch, and the electrical current that flows between them cuts and shapes the substrate. Both electrodes are submerged in a dielectric fluid that flows between them, facilitates control of electrical current, and removes the excess material eliminated by the EDM process.

In order to meet the needs of a variety of applications, numerous EDM machining methods have been developed to create extremely accurate components. Wire EDM and fast hole EDM are two of the most commonly used techniques.

Wire EDM

Wire EDM uses a spool of brass or copper wire that is continuously unwound as the wire moves alongside the substrate, generating sparks that cut through the entire workpiece. This method provides highly accurate, smooth cuts through the substrate, and is ideal for use with complex geometries and precision components. It is important to note that Wire EDM can only be used to cut through a full workpiece.

Fast Hole EDM

Fast hole EDM, also known as sinker or plunge EDM, is specifically engineered to drill precision holes with the utmost speed and accuracy. This method uses a ram or plunger composed of conductive material such as copper, brass, tungsten, or graphite. While wire EDM requires drilling a hole into the substrate to incorporate the wire, fast hole EDM can drill holes of varying depths with an exceptional degree of accuracy. Fast hole EDM is often used to create components for aerospace, manufacturing, medical, energy, automotive, and military and defense applications.

Sinker EDM

Miniature Parts

pins are .012 inch diameter to a depth of .030 inches.

Extreme Accuracy and Fine Finishes

Tolerances of up to +/- .0001″ can be achieved with very fine finishes.

Various Shapes and Sizes In Blind Cavities

Threads Into Hardened Materials, Molds, Hexes Into Bolts, and Keyways. There are many operations where Sinker EDM is the most efficient way to machine parts. Sinker EDM can be done in the vertical or horizontal position. We are able to even EDM parts upside down.

Helical Gears

Orbiting machines can machine helical gears and shapes. Our Sinker EDM machines are capable of orbital, vectorial, directional, conical, horizontal planetary, cylindrical, helical, concave and convex spherical machining.

Production EDM

are excellent for production work and repeatability.

Machining at an Angle

Sinker EDM is capable to machine parts on an angle.

Innovating Machining

By modifying machines, tall parts can be EDMed.

Tall Parts

Tall parts can be machined in large sinker EDM machines.

Heavy Parts

Work tank size 79.5 inches, Y 126.7 inches, Z 53 inches. Table load is 66,000 pounds.

Rotary EDM

Rotary EDM: Multi-Axis Machining

As the chuck rotates, the wire can move in the X, Y direction. Also, the top wire portion of the wire EDM machine can move in the U and V direction. Due to this multi-axis machining process, various shapes can be machined.

Multi-Axis Rotary Wire EDM

With advances with rotary multi-axis rotary wire EDMs, all sorts of complex shapes may be created. from large to micro parts.

Splitting Bar of Aluminum

The chuck slowly rotated as the EDM wire cut in the X direction.

Slots Machining into a Steel Tube

Repeated slots EDMed as the chuck rotates.

Ball, Thin Shank

Since wire EDM can machine various shapes and is a non-contact machining process, it can machine extremely thin parts.

Large Capacity EDM

Wire EDM of parts up to 10,000 lbs.

SyncFab wire EDM wire electrical discharge machining to ultra-large work pieces, which can weigh up to 10,000 lbs. contouring capacity is 32 in. x 40 in. x 18 in. thick.

Heavyweight Parts

A 10,000-lb. part has become a typical job. Had 9,600-lb. molds modified for cutting big molds and parts 8,700-pound, 40 in. x 46 in. x 16 in. thick block is typical of the large core and cavity work for the plastic injection mold industry. Wire EDM reduced the number of operations from six to two and did not destroy the core, which in this case weighs 2,300 lbs. This mold is for a residential recycling bin.

Large cutting dimensions

The large cutting dimensions for a 2-1/2 lbs., 28 in. diameter part for NASA’s Genesis Mission assuring accuracy.

Precise alignment of curved 36 in. lengths

Wire EDM achieved the precise alignment. Forty-nine curved lengths were cut from a single block of aircraft grade aluminum measuring 13in. x 13-1/2 in. x 36 inches tall.

Learn more about our other capabilities

Get precision manufactured parts, faster and cheaper.

OEMs can slash procurement time and costs for precision parts with a supplier network secured by blockchain for anti-counterfeit, recalls and more.