Fathom uses the latest in wire EDM technology to deliver high-quality parts to its customers. Whether time-sensitive, highly complex, high-precision, or short production run related, Fathom will meet the requirements of your project.
Wire electrical discharge machining (EDM) is an effective manufacturing method for electrically conductive, hard, and intricate parts. EDM is often used when conventional manufacturing methods will not work.
Several important factors determine the cost of wire EDM, including the design, material, quantity ordered, and turnaround time.
The wire EDM process allows for geometric and intricate shapes to be machined with a high level of accuracy. Since the machine does not contact or place pressure on the material, very thin metal sections may be cut. The wire EDM method eliminates any cutting stress or distortion. A fine finish is produced, which eliminates the need for finishing procedures.
Wire EDM can cut through even the hardest material. Solid pieces of metal can be machined, eliminating distortion since the material does not need to be heat treated. Any heat applied to the material is minimal and quickly removed by dielectric fluid.
Wire EDM costs are also affected by the volume of parts required. Costs can be lowered by stacking the parts during cutting, which helps to reduce the amount of time required. Generally, most costs are quoted based on the time a job takes on the cutting machine.
Wire EDM is a cost-effective process. As an automated method that offers extreme precision, labor and time are reduced. No custom tooling is required, which helps to cut down on lead times. EDM results in a smooth part, which means a finishing or secondary process is not needed. Since no finishing is needed, the part is produced quickly.
Take advantage of Fathom’s SmartQuote online platform and receive a quote in as little as 1 hour, usually within 24 hours. Do you need a wire EDM quote, or would you like to learn about another manufacturing service? Fathom’s wire EDM lead times are as follows:
Fathom is ready to work with you on your wire EDM job. Let us utilize our single-source global network to support your low- and high-volume projects. By leveraging both additive and advanced technologies, Fathom can produce high-quality parts that will satisfy our customers.
Wire EDM is one of 28 manufacturing processes offered by Fathom.
Wire EDM is a manufacturing process used to cut through electrically conductive materials that may not be machined using conventional methods such as titanium, carbon steel, and tungsten. Sometimes called spark EDM, wire EDM uses a tool to discharge sparks that melt through the material to create an accurate cut. Throughout the process, the workpiece is submerged in water which carries away any material waste. Wire EDM is perfect for parts that require complex geometries and high accuracy. Learn more about wire EDM.
Water jet manufacturing is a manufacturing process that uses water to shape material. During water jet cutting, a pump with a cutting head as small as a human hair generates an extremely high-pressured stream of water. The water is combined with an abrasive (garnet) to cut through thick material such as steel. Water jet cutting is a good match for projects that require an outstanding edge quality. While both wire EDM and water jet cutting are capable of precision and cutting through hard materials, wire EDM is considered more accurate than waterjet. If ultimate accuracy is not required for a part, waterjet cutting may be a suitable option. Learn more about water jet cutting.
Laser cutting uses a high-powered laser to cut raw material. Laser cutting is most commonly used on sheet metal, wood, glass, rubber, and more. During laser cutting, CNC controls the direction of the workpiece and the laser beam. Like wire EDM, laser cutting is capable of clean cuts and high accuracy. Unlike wire EDM, it should not be used to cut through material thicker than 4 inches. Learn more about laser cutting.
Micro cutting or micro water jet cutting is water jet manufacturing on a micro-level. Water jet cutting uses a high-pressure stream of water and an abrasive to cut through the material. Micro cutting is often used to create small components where high accuracy is required. Micro cutting should only be used to make flat parts with a thickness between 0.001” to 0.125”. While wire EDM and micro cutting are highly accurate methods, wire EDM is preferred when working with thicker raw material. Learn more about micro water jet cutting.
Fathom’s manufacturing facilities are powered by over 530 machines, including mills, lathes, presses, press brakes, turret punches and additive systems. Thirty-one of Fathom’s machines are dedicated to wire EDM manufacturing. Fathom’s 31 machines include 16 for wire EDM, 12 for sinker EDM, and 3 for drill EDM. It is our network of state-of-the-art equipment that allows us to offer our customers a rapid turnaround.
Fathom also offers hybridized services that leverage wire EDM. Do you need wire EDM as part of a more complex project? Fathom can deliver. A recent case study illustrates how Fathom manufactured 20,000 parts in 27 days using 55+ tools, including water jet cutting services.:
A customer came to Fathom with a complex project that spanned the technologies and processes of rapid production—and needed it done fast. Fathom delivered.
55+ Tools to Injection
Mold 15,000 Parts
First Article in 2 Weeks
3,000+ 3D
Printed Parts
2,000+ Metal
Fabricated Parts
3D Printing / Additive Manufacturing—PolyJet, SLS, MJF.
DFM Analysis + CAD Mods.
CNC Machining. Laser Cutting.
Stamping. Die Cutting. Post-Opp Drilling.
24-hour Turnaround Urethane Casting.
Injection + Compression Molding.
Model Finishing. Insert Assembly.
Advanced Project Management.
Fathom has 5 US-based locations that offer wire EDM, offering nationwide coverage to the entire United States. Fathom’s advanced prototyping and manufacturing services include injection molding, CNC machining, chemical etching, metal 3D printing, and more. We have provided over 200,000 quotes to leading U.S. companies and are ready to provide you with a quote today.
Wire EDM locations include:
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
ISO 9001:2015
NIST 800-171 Compliant
ITAR
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
1401 Brummel Ave
Elk Grove, IL 60007
ISO 9001:2015 Design Certified
TEXAS
1513 Sam Bass Rd
Round Rock, TX 78681
ISO 9001:2015
ISO 13485:2016
Wire EDM technology facilitates higher cutting accuracies and tighter tolerance than standard cutting methods. A lower power and speed can be used to improve the accuracy of wire EDM. By reducing the power and flushing pressure results in +/- 0.0005” tolerance. Wire EDM provides great precision, even when working with the hardest of raw materials.
| Material Thickness | Tolerance | Kerf | Part Volume | Set Up Cost | Lead Time ** | Notes |
|---|---|---|---|---|---|---|
| 0.001″ – 6″ | 0.0005″ | 0.005″ | 1-200 Is Best | Low | 6-8 days | Conductive Metals, Carbon |
Wire EDM should be used with any conductive metal such as titanium, aluminum, brass, alloys, and superalloys. Thanks to wire EDM’s accuracy, wire EDM has become a popular manufacturing method for various industries. Whether for part or prototype, Fathom has many materials suitable for wire EDM, including:
Wire EDM has multiple benefits that will impact your project. Wire EDM uses an electrically charged wire to cut shapes, making it capable of cutting pieces from fragile and hard materials. Since manufacturing involves little to no impact or pressure on the raw material, even brittle parts can be made using wire EDM. High accuracy is possible as wire EDM machining is considered more precise than laser or plasma cutting. Wire EDM manufacturing is typically a one-step process, which helps to reduce lead time. Lastly, the quick turnaround time and minimal waste of wire EDM make it a cost-effective method.
While wire EDM can produce a smooth, mirror-like finish, some finishing may be needed to customize the part. Some common finishing processes used on wire EDM parts include:
Painting is used to add color, varnish, or ink to a part. Painting methods may include powder coating, liquid coating, or e-coating. The powder is electrostatically charged during powder coating, leaving a scratch-resistant and even coat on the metal part. Liquid coating is when wet paint is applied to a surface. E-coating is the process of dipping a metal part into a bath of paint. The part and paint are electrified, and the paint adheres to the part.
Transfers may be used to add a label or design to a part. The design is placed onto the part, pressure is applied using a heated press, and the design is transferred. This method can also be used to print a design that will later be engraved onto the part.
Assembly is required when the unit manufactured is part of a larger piece. During the assembly step, the workpiece is bonded together with other parts to create the final product. Fasteners or bonding procedures may be used to fuse the parts temporarily or permanently.
Drilling is used to add a round hole. Drilling may be performed using a drill press, tapping, or milling machine. Different types of drills may be used, such as spotting or peck drills, depending on the mark that must be made.
Deburring is used to remove any raised edges or unwanted material known as burrs. Deburring may be achieved using several methods, including electrochemical deburring, thermal deburring, and abrasive flow deburring. Electrochemical deburring uses an anodic metal dissolution to remove unwanted material. Thermal deburring uses a combustible gas in a pressurized chamber to deburr a part. Abrasive deburring uses an abrasive slurry to deburr the part.
Many industries use wire EDM manufacturing, including automotive, aerospace, electronics and more. Wire EDM is a highly accurate process capable of outstanding feature resolutions using fragile and hard materials. Examples of wire EDM parts include:
A: Yes, Fathom offers wire EDM machining.
A: Wire EDM is the process of machining metal that uses a tool to discharge sparks onto metal material. The discharge melts the material, creating an accurate cut.
A: Fathom’s certifications include ISO 9001:2015, ISO 9001:2015 Design, and ISO 13485:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is ITAR certified. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom is AS9100:2016. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: Yes, Fathom’s certifications include NIST 800-171. For site-specific certifications, please visit https://fathommfg.com/fathom-manufacturing-certifications.
A: The cost of wire EDM depends on the number of parts, raw material chosen, the complexity of design, and more. Use our SmartQuote platform to get a quote today.
A: Wire EDM stands for wire electrical discharge machining.
A: While both EDM and wire EDM use an electrical discharge to shape material, wire EDM is capable of more complex shapes than conventional EDM.
Are you looking to get Wire EDM quotes or calculate costs for an upcoming project? Fathom’s SmartQuote application provides fast quotes for any file. Receive a quote in as little as one hour.
Precision manufacturing
from coast to coast.
HEADQUARTERS //
1050 Walnut Ridge Drive
Hartland, WI 53029
877-328-4668
ARIZONA
444 W. 21st St. Ste. 101
Tempe, AZ 85282
480-966-2300
CALIFORNIA
46758 Lakeview Blvd
Fremont, CA 94538
COLORADO
7770 Washington St.
Denver, CO 80229
303-288-6855
FLORIDA
14000 N.W. 58th Court
Miami Lakes, FL 33014
305-889-3280
ILLINOIS
1207 Adams Drive
McHenry, IL 60051
815-385-7500
1401 Brummel Ave
Elk Grove, IL 60007
847-952-8088
MINNESOTA
13758 Johnson Street NE
Ham Lake, MN 55304
763-755-7575
NEW YORK
1920 Slaterville Rd.
Ithaca, NY 14850
607-277-7070
401 W. Shore Blvd.
Newark, NY 14513
315-331-7680
TEXAS
1513 Sam Bass Rd.
Round Rock, TX 78660
512-255-1477
