Electrical Discharge Machining, EDM is one of the most accurate manufacturing processes

available for creating complex or simple shapes and geometries within parts and assemblies.
EDM works by eroding material in the path of electrical discharges that form an arc between an
electrode tool and the work piece. EDM manufacturing is quite affordable and a very desirable
manufacturing process when low counts or high accuracy is required. Turn around time can be
fast and depends on manufacturer back log.

The EDM system consists of a shaped tool or wire electrode, and the part. The part is connected
to a power supply. Sometimes to create a potential difference between the work piece and tool,
the work piece is immersed in a dielectric (electrically nonconducting) fluid which is circulated
to flush away debris.

The cutting pattern is usually CNC controlled.

Many EDM machine electrodes can rotate about
two-three axis allowing for cutting of internal
cavities. This makes EDM a highly capable
manufacturing process.

EDM comes in two basic types: wire and probe

(die sinker). Wire EDM is used primarily for
shapes cut shapes through a selected part or
assembly. With a wire EDM machine, if a cutout
needs to be created, an initial hole must first be
drilled in the material, then the wire can be fed
through the hole to complete the machining.
Sinker (diesinking) EDMs are generally used for
complex geometries where the EDM machine
uses a machined graphite or copper electrode to
erode the desired shape into the part or assembly.
Sinker EDM can cut a hole into the part without
having a hole pre-drilled for the electrode.

Design Considerations

Relax the surface-finish for the part, if feasible. This allows the manufacturer to produce
the part with fewer passes, at a higher current level and a higher metal-removal rate.
Design or prepare the part such that the amount of stock removed by EDM is relatively
small. Use traditional machining techniques to remove the bulk of the stock with the
finishing operations performed by EDM. This significantly reduces the amount of time
and cost for each part.
The EDM manufacturer should consider fixtures such that several parts can be stacked
and machined simultaneously or a single part can have several EDM operations
performed simultaneously.
When existing holes are to be enlarged or reshaped by EDM, through holes are preferred
to blind holes as they permit easier flow of dielectric fluid past the area being machined
Dimensional Accuracy (+/- 0.0005 inches per inch)
Feature Profile accuracy of .0003 is obtainable with cutting path
Features to feature true position of .002 is reasonable and down to .001 is possible when
geometry requires removal and reattachment of wire.

Surface Finish (microinches) Features created by EDM have an "orange peal" appearance.
16 Ra is achievable, 64 or higher Ra is typical and less expensive.

Wall Thickness
Min Wall Thickness (inches): 0.01 (over a 5" inch span)

As always, consult with EDM vendor for specific capabilities.