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.
- Lead times from 5 business days
- Quotes for up to 10,000 parts
- 50+ metals and plastics, 20+ surface finishes
- Rapid prototyping and full-scale production
- Tolerances down to ±.0008’’ (0.020 mm)
- AS9100, IATF 16949, ISO 13485, ISO 9001
Accelerate Your Production Lead Times
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.
CNC Materials
Aluminum
Available Aluminum Varieties:
- Aluminum 5052
- Aluminum 7075
- Aluminum 7075-T6
- Aluminum 6063-T5
- Aluminum 7050-T7451
- Aluminum MIC-6
- Aluminum 6061-T6
- Aluminum 2024-T3
Brass/Bronze
Available Brass/bronze Varieties:
- Bronze C903
- Bronze C905
- Bronze C907
- Bronze C916
- Bronze C862
- Bronze C863
- Bronze C864
- Bronze C865
- Bronze C867
- Bronze C932
- Bronze C934
- Bronze C935
- Bronze C936
- Bronze C937
- Bronze C938
Copper
Available Copper Varieties:
- Copper 101
- Copper 110
- Copper 122
- Copper 145
- Copper 147
- Copper 172
- Copper 182
Plastic
Available Plastic Varieties:
- Acrylonitrile Butadiene Styrene (ABS
- Acrylic (PMMA)
- Nylon
- Polylactide (PLA)
- Polycarbonate (PC)
- Polyether Ether Ketone (PEEK)
- Polyethylene (PE)
- Polyurethane (PU)
- Polyvinyl Chloride (PVC)
- Teflon (PTFE)
Steel
Available Steel Varieties:
Alloy Steel
- EDT150
- 41L40
- 86L20
- 4130
- 4140
Carbon Steel
- A36, A529-50
- A311, A366
- A513, A514
- A569, A572
- A588, A606
Tool Steel
- A-2, A-6, D-2
- DC-53, G2
- L-6, M-2, M-4
- O-1, O-6, P-20
- S-5, W-1, H-13
Stainless Steel
- N50, N60, 13-8
- 5-5, 17-4, 201
- 302, 303, 304
- 304L, 316, 316L
- 321, 347, 410
Titanium
Available Titanium Varieties:
- Titanium 6AL-4V
- Titanium 6AL-4V ELI
Zinc
Zinc
Zinc, a crystalline metal with moderate strength and ductility, is seldom used alone except as a coating. Highly workable and highly forgeable wrought-zinc alloys containing Ti, Al, Pb, Cd, Cu, or Fe in various quantities are easily machined.
CNC Finishes
As-milled
The finish option with the quickest turnaround. Parts are left with visible tool marks and potentially sharp edges and burrs, which can be removed upon request. Surface finish is comparable to 125 uin Ra finish.
Bead Blast
Anodized
(Type II & Type III)
Type II (MIL-A-8625, Type II) creates a corrosion-resistant finish. Parts can be anodized in different colors—clear, black, red, and gold are most common—and is usually associated with aluminum. Type III (MIL-A-8625, Type III, Class 1/2 “hardcoat”) is thicker and creates a wear-resistant layer in addition to the corrosion resistance seen with Type II.
Powder Coat
This is a process where powdered paint is sprayed onto a part that is then baked in an oven. This creates a strong, wear- and corrosion-resistant layer that is more durable than standard painting methods. A wide variety of colors are available to create the desired aesthetic.
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.
Space
Oil & Gas
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Aerospace & Defense
Maritime
![](/wp-content/uploads/2021/01/Automotive.png")
Automotive
Medical
Space
Aerospace & Defense
Automotive
Oil & Gas
Maritime
Medical
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.
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 of virtually any tough or exotic conductive materials
- Absolute accuracy and repeatability EDM
- EDM Contract Manufacturing
- EDM cutting of Prototype to Production runs of nearly any geometric intricate EDM shape
- Complete EDM Machine shop and support
- EDM Machining tolerances held to .0002”
- EDM hole drilling as small as .010”
- Superior ultra fine surface finishes
- EDM High Speed Drilling
- 30º Tapers Up to 15” inch thick
- EDM Cuts up to 24” inch thick
- EDM Capacities to 24” thick and 2000 lbs
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.
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
CNC Machining
Prototypes and precision production parts expedited to meet your build time requirements
Sheet Metal
Sheet Metal part prototypes and precision production parts expedited to meet your build time requirements
3D Printing
3D printed prototypes and precision production parts expedited to meet your build time requirements
Molding
Molding prototypes and precision production parts expedited to meet your build time requirements
Casting
Casting prototypes and precision production parts expedited to meet your build time requirements
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.
