Wire EDM Services for Precision Cut Metal Parts
Factory-direct wire EDM cutting for hard conductive metals, tight slots, complex profiles, precision tooling, punches, dies and plate-like components. Upload your CAD files for process review, tolerance evaluation, cutting strategy and inspection planning.
Precision Through-Cut Profiles
For plates, inserts, punches, dies and profile-cut parts.
Hard Conductive Metals
Hardened steel, tool steel, stainless steel and titanium reviewed.
Tight Slots & Fine Contours
Narrow slots, complex outlines and small internal radii.
Low Cutting Force
Useful for thin, delicate or hard metal profiles.
Inspection Reports
Profile, slot width and dimensional reports available.
Is wire EDM right for my part? | Wire EDM is suitable for electrically conductive materials that require precise through-cut profiles, tight slots, sharp internal corners or low cutting force. |
Can wire EDM cut hardened steel? | Yes. Wire EDM can cut conductive hard metals, including hardened steel and tool steels, when the geometry fits through-cut machining. |
Can wire EDM produce tight slots? | Yes. Wire EDM can produce narrow slots, precise profiles and fine internal features that are difficult with milling tools. |
Can wire EDM cut blind cavities? | No. Wire EDM cuts through the workpiece. Blind cavities and electrode-shaped 3D features are usually better reviewed for sinker EDM. |
Can wire EDM reduce deformation risk? | Wire EDM uses very low cutting force, which can help reduce deformation risk for thin, delicate or hard metal parts. |
Can you inspect wire EDM parts? | Dimensional inspection, profile checks, slot width checks and inspection reports are available based on project requirements. |
Turning Capability
Wire EDM Cutting Capability
Before quoting, our engineers review material conductivity, thickness, profile complexity, internal radii, slot widths, start-hole requirements, kerf compensation and inspection needs.
| Capability Area | Manufacturing Range | Best For |
|---|---|---|
| Precision Through-Cut Profiles | Wire EDM cuts through conductive material using a moving wire electrode. | Plates, inserts, punches, dies, templates and profile-cut parts. |
| Hard Metal Cutting | Wire EDM can cut hardened and difficult-to-machine conductive materials. | Hardened steel, tool steel, stainless steel, titanium and selected carbide applications. |
| Tight Slots & Fine Contours | Narrow slots, fine profiles and small internal radii can be reviewed. | Precision slots, internal shapes, gear-like forms and intricate contours. |
| Low Cutting Force Process | Material is removed by electrical discharge instead of mechanical cutting force. | Thin sections, delicate profiles and parts sensitive to clamping or cutting stress. |
| Stacked Cutting Review | Multiple thin parts may be reviewed for stack cutting depending on material and tolerance. | Thin plates, shims, washers, precision blanks and repeat profiles. |
| Inspection Support | Dimensional checks, profile verification and reports available when required. | Critical profiles, slot widths, hole locations, datum features and tooling inserts. |
Process Fit
When to Choose Wire EDM Cutting
Wire EDM cutting is often selected when a conductive metal part requires precise through-cut geometry, tight internal profiles, narrow slots or low cutting force. It is especially useful for hardened materials, tool steels, thin profiles and complex shapes that are difficult to machine with conventional cutting tools.
Blind cavities are usually better suited for sinker EDM machining. Standard pockets and flat surfaces may be more cost-effective with CNC milling service. Round parts may be better suited for CNC turning service.
Choose wire EDM when
The part has through-cut contours, tight slots, hard conductive material or small internal radii.
Choose sinker EDM when
The part requires blind cavities, electrode-shaped internal geometry or deep 3D features.
Choose milling when
The part mainly has accessible pockets, flat surfaces, holes or standard machined features.
Ask for process review when
You are unsure whether wire EDM, sinker EDM, CNC milling or a combined process is most practical.
Process Comparison
Wire EDM vs Sinker EDM vs CNC Milling
Wire EDM is best for through-cut shapes. Sinker EDM is better for blind cavities and electrode-shaped internal geometry. CNC milling is usually more efficient for accessible surfaces, pockets and standard drilled or tapped features.
01
Wire EDM
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Sinker EDM
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CNC Milling
Part Types
Wire EDM Parts We Support
Baosheng supports wire EDM cutting for hard conductive materials, precision through-profiles, tooling components, tight slots and plate-like metal parts where low cutting force and profile accuracy are important.
- Tool steel punches
- Die inserts
- Precision plates
- Hard metal profiles
- Thin metal shims
- Cutting templates
- Mold components
- Press tooling components
- Gear-like profiles
- Precision washers
- Complex 2D contours
- Medical tooling components
- Electronics tooling inserts
- Aerospace-style brackets and plates
- Automotive tooling components
- Carbide wear parts
Materials & Finishes
Materials and Post-Processing for Wire EDM Parts
Wire EDM works only on electrically conductive materials. It is commonly used for hardened steel, tool steel, stainless steel, titanium, aluminum, copper and selected carbide applications where precise through-cut geometry or low cutting force is required.
Wire EDM produces a spark-eroded cut surface. Surface finish depends on cutting parameters, material, wire condition and the number of skim cuts. Parts may require cleaning, deburring, passivation or additional post-processing depending on application requirements.
Tool Steel
Punches, dies, inserts and precision tooling profiles.
Hardened Steel
Wear-resistant profiles, hardened plates and tooling components.
Stainless Steel CNC Machining
Precision plates, thin parts and corrosion-resistant profiles.
Titanium CNC Machining
Difficult-to-machine precision profiles and aerospace-style parts.
Aluminum CNC Machining
Prototype plates, lightweight profiles and precision cut parts.
Copper CNC Machining
Conductive profiles, electrical parts and EDM-related components.
Passivation
Corrosion resistance for stainless steel wire EDM parts.
Electropolishing
Smoother surfaces for selected stainless steel profiles.
Not sure whether wire EDM is required?
Upload your CAD files and our engineers will review material, thickness, profile geometry, start-hole needs, kerf compensation and inspection requirements before quoting.
Quality Control
Tolerance, Kerf Width and Inspection
Wire EDM accuracy depends on material, thickness, profile complexity, wire diameter, kerf width, cutting strategy, skim cuts and inspection method. Baosheng reviews CAD models and 2D drawings to identify critical profiles, datum references, slot widths and inspection requirements before production.
Drawing Review
Profiles, slots, thickness and datum references identified.
Process Review
Conductivity, start holes and cutting path reviewed.
Kerf Planning
Wire diameter, kerf compensation and skim cuts reviewed.
Cutting Strategy
Stack cutting, handling and deformation risks reviewed.
In-Process QC
Critical slots, profiles and dimensions checked as needed.
Final Inspection
Optical, CMM, gauges or manual checks based on drawing.
Report
Dimensional report available upon request.
Application Proof
Wire EDM Case Studies
The cases below focus on realistic wire EDM applications: through-cut profiles, hardened metals, tight slots, thin shims, low cutting force and inspection planning.
| Project | Material / Process | Challenge | Inspection / Result |
|---|---|---|---|
| Tool Steel Punch with Complex Profile | Tool steel · wire EDM + deburring · 40 pcs | Complex through-cut profile and small internal radii after heat treatment. | Wire EDM maintained profile accuracy without cutting-tool access limits; optical inspection checked critical radii and profile dimensions. |
| Hardened Steel Die Plate with Tight Slots | Hardened steel · wire EDM + cleaning · 24 pcs | Multiple tight slots and high hardness made conventional milling inefficient. | Controlled kerf compensation improved slot accuracy; slot width, position and profile were checked before shipment. |
| Stainless Steel Precision Shim Set | 304 stainless steel · wire EDM stack cutting + deburring · 300 pcs | Thin parts required consistent profile accuracy with low cutting force. | Stack cutting feasibility was reviewed; thickness, profile and edge condition were checked by sampling inspection. |
| Titanium Bracket with Fine Internal Profile | Titanium Grade 5 · CNC roughing + wire EDM profile cutting · 60 pcs | Internal profile and corner radii were difficult to finish with standard milling tools. | CNC roughing handled accessible features; wire EDM finished the precision internal profile and reduced cutting-force-related risk. |
Project Workflow
How to Order Wire EDM Cut Parts
1.Upload CAD
Send 3D CAD and 2D drawings with profile and tolerance notes.
2.Process Review
Material, thickness, start holes and through-cut geometry reviewed.
3.Cut Strategy
Kerf compensation, cutting path and skim-cut needs planned.
4.Quote
Receive pricing, lead time and engineering notes.
5.Wire EDM & QC
Parts are cut and inspected based on drawing requirements.
6.Delivery
Parts are cleaned, packed and shipped for your schedule.
Industries
Wire EDM Cutting for Precision Manufacturing Applications
Mold & Tooling
Punches, dies, inserts, templates and tool steel profiles.
Medical Devices
Tooling components, thin stainless profiles and precision fixtures.
Electronics
Connector tooling, small profiles and precision inserts.
DFM Guidance
Design Tips for Wire EDM Parts
For wire EDM parts, manufacturability depends on material conductivity, material thickness, through-cut geometry, start holes, inside corner radii, kerf compensation and inspection requirements. A 2D drawing is strongly recommended for slot widths, tolerances and profile notes.
- Confirm the material is electrically conductive.
- Wire EDM requires a through-cut path through the workpiece.
- Internal profiles may require start holes before cutting.
- Allow engineering review for wire diameter and kerf compensation.
- Provide material thickness information for cutting strategy review.
- Define which internal corners require small radii.
- Thin or stress-relieved parts may require flatness review after cutting.
For broader pricing factors, review CNC machining cost.
Your questions answered
Wire EDM FAQs
When should I choose wire EDM?
Wire EDM is recommended when your part requires precise through-cut profiles, tight slots, hard conductive materials, small internal radii or low cutting force.
What is the difference between wire EDM and sinker EDM?
Wire EDM uses a moving wire to cut through conductive material. Sinker EDM uses a shaped electrode to machine blind cavities and internal 3D features.
Can wire EDM cut hardened steel?
Yes. Wire EDM can cut conductive hardened materials, including hardened steel and tool steel, when the part geometry fits the process.
Can wire EDM cut non-conductive materials?
No. Wire EDM requires electrically conductive materials. Non-conductive plastics and ceramics usually require other manufacturing processes.
Does wire EDM create cutting force?
Wire EDM has very low mechanical cutting force because material is removed by electrical discharge instead of conventional tool pressure.
Can wire EDM cut blind cavities?
No. Wire EDM is a through-cut process. Blind cavities are usually better reviewed for sinker EDM machining.
What tolerances can wire EDM achieve?
Tolerance depends on material, thickness, profile complexity, wire diameter, cutting strategy and inspection method. Critical tolerances should be reviewed from a 2D drawing.
Do wire EDM parts need post-processing?
Some wire EDM parts may require cleaning, deburring, passivation, polishing or additional surface treatment depending on edge condition, material and application.
What files do you need for a wire EDM quote?
We recommend 3D CAD files and 2D drawings with material, thickness, profile tolerance, slot width, surface finish and inspection requirements.
Can you sign an NDA before reviewing wire EDM files?
Yes. NDA can be arranged before file review when your project requires confidentiality.
Get a Quote for Wire EDM Cut Parts
Upload CAD files and drawings with material, thickness, profile geometry, slot width, tolerance, surface finish and inspection requirements. Our engineers will review wire EDM feasibility, start-hole needs, kerf compensation, cutting strategy and inspection planning before quoting.
- NDA available before file review
- Wire EDM process and kerf compensation review
- Start-hole and through-cut profile review
- Profile and slot inspection reports available
- Multiple CAD and drawing files supported
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