High precision and tight tolerances for complex components
In applications where every micrometre counts and a high-quality surface finish is required, wire EDM offers an unmatched solution. Unlike conventional milling or turning, where mechanical forces act on the workpiece, wire EDM cuts through the hardest metals completely contact-free and stress-free.
At Tumag, wire EDM is an absolute core competence. We use this advanced EDM technique (Electrical Discharge Machining) every day for demanding disciplines. Discover what we can do for your projects in mould making, the production of high-end cutting dies, or complex precision mechanics. Thanks to many years of experience, highly skilled specialists and continuous investments in our machine park, we have mastered this machining technique to perfection.
What is wire EDM?
Wire EDM is a form of spark erosion, an extremely precise machining technique in which a thin, continuously moving and electrically charged wire removes material from electrically conductive workpieces.
Through controlled electrical discharges (sparks) between the wire and the workpiece, the material melts away locally. This process offers a crucial advantage: there is no mechanical contact. Because the machining process takes place entirely in a dielectric fluid, it ensures maximum stability and highly efficient, accurate material removal.
Why choose wire EDM? The key benefits
Thanks to the unique properties of the wire EDM process, it offers significant advantages over traditional machining techniques. We have clearly listed the key strengths for you below:
- Complex contours and fine details: Perfect for sharp internal corners, small radii and intricate 2D and 3D profiles.
- Stress-free machining: Because there is no physical contact, no mechanical stresses are introduced into the workpiece. Ideal for parts that need to remain structurally stable.
- Highly suitable for hard materials: Unlike traditional machining techniques, the EDM process is exceptionally well suited for machining extremely hard or already hardened materials, without compromising high precision.
- Excellent surface quality: Through optimised cutting strategies and multiple skim passes, we achieve extremely low roughness values.
- Less post-processing: Finishing operations such as grinding or polishing are often unnecessary, resulting in shorter lead times and lower costs.
Applications and materials
Hard and high-grade materials
Wire EDM is the perfect choice for machining materials where conventional milling or turning falls short. We machine hard materials such as tool steel, carbide, hardened alloys and other extremely wear-resistant materials with ease.
Tailor-made solutions for demanding industries
Thanks to its high geometric freedom, this technique is ideally suited for the production of:
- Complex mould components and precision inserts
- Cutting dies
- Precision mechanical and functional components
Your partner in precision: Micron-level accuracy at Tumag
Tumag has an ultra-modern machine park with advanced wire EDM machines capable of achieving accuracies in the micrometer range. By combining modern technology with thorough process control, we consistently guarantee reliable and reproducible results. Whether it concerns one-off parts, complex prototypes or small to medium-sized series, every product is manufactured with the same care.
As a reliable partner, we actively think along with you from the very start. From the initial design to the finished product, we are happy to advise you on manufacturability, tolerances and the most optimal machining strategies.
Are you looking for a reliable partner for your wire EDM products? Then choose the certainty, precision and quality of Tumag.
Frequently Asked Questions about Wire EDM (FAQ)
Which materials can be machined using wire EDM?
The only requirement for wire EDM is that the material must be electrically conductive. This means we can machine virtually all metals, including aluminium, copper, bronze, stainless steel, tool steel, titanium and carbide.
What is the difference between wire EDM and sinker EDM?
Both techniques use electrical discharges to remove material. In wire EDM, a thin wire acts as the electrode to cut contours out of the material (similar to a scroll saw). In sinker EDM (Die Sinking EDM), a custom-made electrode (often made of copper or graphite) in the shape of the desired cavity is used, which effectively “sinks” into the material.
How precise is wire EDM at Tumag?
Wire EDM is one of the most precise machining techniques in the world. At Tumag, we can achieve dimensional accuracies down to just a few micrometres (thousandths of a millimetre). This is essential in precision mechanics and mould making, where even the smallest deviation is unacceptable.
Can wire EDM eliminate the need for secondary finishing operations?
Yes, in many cases. Because wire EDM allows us to achieve very low surface roughness and extreme dimensional accuracy, expensive or time-consuming secondary finishing operations such as cylindrical grinding or surface grinding are often no longer necessary.
Why is wire EDM so popular in mould making?
Moulds require extremely tight tolerances and are often made from very hard tool steel or carbide to prevent wear. Because wire EDM cuts hard materials effortlessly without applying mechanical force to the workpiece, it is the most reliable and precise method for producing mould components, punches and inserts.