Wire
EDM
complex profiles with
±0.0001″ accuracy
Twin City EDM & MFG provides wire EDM services for parts that demand tight tolerances, intricate geometries, and exceptional edge quality. Wire as small as 0.004″ is used to machine conductive materials into detailed profiles without inducing stress or altering metallurgical properties.
Whether you’re developing a one-off prototype or scaling to high-volume production, our team combines speed, repeatability, and micron-level accuracy to help you move from design to finished part without compromise.
What Is Wire Electrical Discharge Machining (EDM)?
Wire EDM (Electrical Discharge Machining) is a non-contact cutting process that removes material using thermal energy instead of mechanical force. A thin, electrically charged wire cuts through conductive materials by generating controlled sparks that erode the workpiece along a programmed path. This process happens in a DI water that flushes away debris and cools the part to prevent distortion.
Unlike conventional machining, wire EDM does not rely on cutting pressure or rotating tools. This allows machining of hard, brittle, or heat-treated materials without causing burrs, warping, or mechanical stress. Because the wire never physically touches the part, we can create fine features and sharp internal corners that would be impossible with traditional tooling.
How Wire EDM
Helps Complex Parts
Take Shape
Many parts manufactured with wire EDM involve features that would be difficult or impossible to cut using standard milling or turning. We often use this process when tight internal radii, narrow slots, or extremely thin walls are required. Below are a few examples of how our clients use wire EDM in real-world applications:
Medical Marker Radials:
We cut precision slits and radiused ends in stainless steel for optical marker radials. The no-stress EDM process ensures flawless accuracy and uniformity, which is essential for medical imaging devices and surgical navigation tools.
View our case study here.
Aircraft Sleeves:
For pedo static sleeves used in aerospace systems, we machine slots and internal contours that require exact repeatability. Wire EDM provides the accuracy needed to meet aviation standards without deforming the sleeve wall.
Learn more here.
Dental Instruments:
When machining surgical guides or needle placement instruments, our team uses EDM to produce ultra-fine holes and narrow channels in hardened stainless steel, where tool deflection or burrs would otherwise compromise functionality.
View our case study here.
Wire EDM excels in situations where the geometry is complex, the material is tough, and the tolerance requirements are tight. It is ideal for producing detailed shapes in a single setup, minimizing secondary operations and improving throughput.
Materials We Can Cut With Wire EDM
Wire EDM only works on conductive materials. This includes a wide range of metals and alloys, from standard grades to exotic materials engineered for extreme performance. Because the process uses electrical discharge, it is well-suited to materials that are difficult to machine using traditional methods, such as hardened steels or superalloys.
Some of the materials we can use are:
- Stainless Steel
- Steel and Tool Steel
- Aluminum
- Titanium
- Carbide
- Graphite
- Copper
- Brass
- Bronze
- Nickel
- Tin
- Lead
- Castings
- Powdered Metals
- Conductive Ceramics
- Inconel
- Kovar
- Nitinol
- Gold
- Molybdenum
- Niobium
We frequently EDM parts from heat-treated stainless, titanium, and specialty materials like Nitinol and Kovar, especially when clean edges and dimensional stability are critical.
Talk to Our Wire EDM Specialists
If you’re working on a part that requires high accuracy, tight contours, or a hard-to-machine material, wire EDM could be the best fit. Twin City EDM has over 60 years of experience helping OEMs and manufacturers produce mission-critical parts across industries. From fast-turn prototypes to ongoing production runs, we deliver the consistency and service our clients depend on.
Contact our team or request a quote today to discuss your next project.