Wire EDM: the route, the tolerances it holds, materials and design tips, with an indicative cost. One of 56 processes in the free finder.
Non-traditionalFamily
+/-0.005mmTypical tol.
5Route steps
10Parts in finder
Wire EDM cuts conductive metal with a travelling charged wire that erodes a precise profile right through the part.
At a glance
When to use it, and when not
Best for
Precise 2D profiles in hardened metal: dies, punches, gears and medical blanks.
Watch for
Through-profile cuts only (with taper), slow, and conductive materials only.
Step by step
The typical route
Raw material to finished part. Steps vary with material, volume and tolerance; this is the free route from the finder.
Thread wire
Thread the wire and set datums.
Tooling Wire EDM Tolerance - Lead -
Rough cut
Rough-cut the profile.
Tooling - Tolerance - Lead -
Skim
Skim passes for tolerance and finish.
Tooling - Tolerance - Lead -
Clean
Clean the part.
Tooling - Tolerance - Lead -
Inspect
Check profile and edge.
Tooling - Tolerance - Lead -
Precision
Tolerances it can hold
TYPICAL TOLERANCE IT CAN HOLD
Where this process typically lands. Tighter is possible with extra operations like grinding, at higher cost.
Materials
Materials it suits
Grade
Why it suits this
Tool steel (hardened)
Cut after hardening
Carbide
Very hard
Any conductive metal
Clean precise edges
Design
Design tips
A few general pointers for Wire EDM. The full, part-specific DFM list is in the dossier.
True 3D contour required.Use sinker EDM or milling.
Over-tight tolerance everywhere.Tight only where it fits.
Cost
What it costs
Wire EDM for precise 2.5D profiles in hardened/conductive material; great for low volume, no custom tooling.
PER-PART COST vs VOLUME
Per-part cost drops as volume spreads tooling and setup over more parts. The exact figures for your part at your volume, in your currency, are in the dossier.
MODEL EST.
$65 to 185per part at 1 off
A rough ballpark only. The dossier gives should-cost at your exact volume and currency, with the full breakdown.
GET THE FULL DOSSIER
Everything you need to quote and source it
The free route above is yours. To actually put a number on this process and buy it well:
Should-cost at your exact volume in 12 currencies, with the material, processing, tooling and overhead breakdown
Who to source from, typical MOQ and lead time, and the exact RFQ checklist to send
A quote checker that tells you if a supplier quote is fair, and the red flags to watch
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Wire EDM cuts conductive metal with a travelling charged wire that erodes a precise profile right through the part. The typical route is: Thread wire; Rough cut; Skim; Clean; Inspect. Precise 2D profiles in hardened metal: dies, punches, gears and medical blanks.
What does Wire EDM cost per part?
It depends on size, tolerance and volume. As a rough ballpark it starts around $65 to 185 per part at low volume and falls with quantity. The dossier gives should-cost at your exact volume and currency. Model estimates, not quotes.
What tolerance can Wire EDM hold?
Typically about +/-0.005 mm, tighter with extra finishing operations at higher cost.
What materials suit Wire EDM?
Common choices are Tool steel (hardened) (Cut after hardening); Carbide (Very hard); Any conductive metal (Clean precise edges).
See the exact route and should-cost for your part
The free finder maps your part to its process and full route. Pro adds should-cost at your volume, sourcing and an RFQ draft.
