Wire EDM Services
High‑accuracy wire cutting for complex geometries, burr‑free finishes, and tight tolerances that traditional CNC machining can’t achieve. Ideal for aerospace, medical, automotive, and industrial components made from hard or exotic metals.
Wire EDM Machining Services
Our CNC wire EDM machining services provide high-precision cutting for complex geometries and tight-tolerance parts, with accuracy up to ±2 µm (0.0001″). Using advanced wire electrical discharge machining (EDM) technology, we can process a wide range of electrically conductive materials, including tool steel, stainless steel, tungsten, carbide, aluminum, copper alloys, and precious metals. Our capabilities include micro wire EDM cutting with wire diameters as small as 20 µm (0.0008″), enabling intricate shapes, narrow slots, and micro features that are difficult to achieve with conventional CNC machining. With flexible production volumes and consistent quality control, we deliver precise, repeatable components for demanding industries and applications.
Why Work With Us？
Quality Assurance
Strict process controls and inspections for reliable, repeatable parts.
Advanced Technology
Modern Wire EDM equipment and CAD/CAM systems for complex geometries.
On-Time Delivery
Efficient planning to meet project deadlines and production schedules.
Professional Facilities
Clean, organized machining environment ensures stable, high-quality outcomes.
Customer-Focused
Tailored solutions and support to meet your unique project needs.
Wire EDM Capabilities
Our CNC wire EDM machining capabilities deliver ultra-precise cutting for complex geometries and tight-tolerance components. We achieve tolerances up to ±0.0001″ (±2 µm) and machine parts up to 16″ thick, supporting 4-axis cutting, high tapers, and intricate contours. Our equipment uses small-diameter wires down to 0.004″, auto-threading systems, and submerged cutting technology for thermal stability and efficient interrupted cutting. With advanced power supplies and multi-pass EDM processes, we ensure excellent accuracy, surface quality, and repeatability across prototype, medium-volume, and high-volume production. Continuous “lights-out” manufacturing and optimized part nesting also help reduce lead times and material waste while maintaining consistent precision.
Materials for Wire EDM
Our Wire EDM services accommodate a wide range of metals and alloys to meet diverse application requirements. We machine hardened tool and alloy steels for dies, molds, and precision tooling, as well as stainless steel for corrosion-resistant, long-lasting components. For lightweight yet high-strength applications, we handle titanium and aluminum, while copper and beryllium copper are ideal for electrical and tooling parts requiring excellent conductivity. We also process carbide for wear-resistant components, nickel and Inconel alloys for high-temperature and aerospace applications, Hastelloy for high-performance corrosion-resistant parts, Kovar for components requiring controlled thermal expansion, and molybdenum and tungsten for specialized high-melting-point applications. Don’t see your material? Contact us—our Wire EDM capabilities can often be adapted to other metals and alloys.
Wire EDM Tolerances
Wire EDM machining delivers highly precise and repeatable results, with standard tolerances typically around ±0.005 mm (±0.0002″). Tighter tolerances are available depending on the material, part geometry, and thickness, while maintaining smooth, burr-free edges and minimal heat-affected zones. This process ensures consistent dimensional accuracy and surface quality across prototypes and production runs, making it ideal for components requiring exacting specifications.
Wire EDM Design Considerations
- Conductive Materials Required – Wire EDM only works with electrically conductive materials.
- Minimum Internal Radius – Limited by wire diameter; small wires allow tighter internal corners.
- Thin Walls & Narrow Slots – Ideal for delicate features that are difficult with conventional machining.
- Part Thickness – Thick materials can be machined, but cutting time increases with thickness.
Wire EDM Surface Finishing
After Wire EDM machining, parts undergo advanced surface finishing processes to ensure precision, durability, and consistent quality. These processes include deburring and polishing to remove micro-burrs and smooth edges, electropolishing to eliminate recast layers and reduce residual stress, and stress relief treatments to maintain dimensional stability for complex or thick components. Optional surface coatings or chemical treatments, such as plating, passivation, or oxidation, can enhance corrosion resistance, wear performance, and overall durability. Together, these finishing techniques ensure that Wire EDM parts meet strict tolerances, surface quality standards, and performance requirements for demanding industries such as aerospace, medical devices, and precision tooling.
Quality Standards & Certifications
Quality is built into every stage of our manufacturing process. From material verification to final dimensional inspection, we use advanced inspection equipment such as CMM measurement, SPC monitoring, and precision inspection systems to ensure every component meets required tolerances and performance standards. Our production processes follow internationally recognized quality systems, including ISO 9001:2015 certification, ensuring consistent accuracy and reliability. Supported by our comprehensive Quality Assurance procedures, we carefully inspect critical dimensions and maintain strict process control to deliver high-precision wire EDM parts that meet or exceed industry standards.
Our Wire EDM Factory
With over 20 years of experience, Xtproto has been delivering precision Wire EDM and electrical discharge machining services for complex metal components and custom tooling. we have continuously expanded and upgraded our EDM capabilities, now operating a fleet of advanced Mitsubishi Wire EDM machines to produce molds, dies, and two-dimensional metal parts with micron-level tolerances. Our highly trained engineers and machinists collaborate closely with clients to develop tailored machining solutions, whether for high-volume production or specialized prototypes, and we have the flexibility to scale production from mold fabrication to large part orders efficiently. Leveraging decades of industry expertise and cutting-edge technology, we consistently deliver high-precision components from challenging materials such as Inconel, tool steels, and specialty alloys, meeting the strictest specifications while maintaining competitive pricing and rapid lead times. At Xtproto, our commitment to quality, innovation, and customer collaboration ensures that every Wire EDM project meets global standards and the exacting needs of aerospace, medical, automotive, and industrial applications.
Wire EDM Machining Parts We Serve
Other EDM Services
Sinker EDM
Hole Popper EDM
Free Wire EDM Service Quotes
At Xtproto, we provide precision Wire EDM and high-speed small hole EDM services to clients around the world. With advanced equipment and extensive production experience, we can handle projects of any size or complexity, delivering high-quality parts on schedule.Have questions or ready to start your project? Contact us online today or request your free quote to get started.
WhatIs Wire EDM Machining & How It Works
Wire EDM machining is a precision process that uses a thin, electrically charged wire to cut electrically conductive metals without direct contact, producing parts with sharp corners, intricate angles, and complex geometries without deformation or mechanical stress. The cutting occurs in a dielectric fluid, which protects the workpiece, removes debris, and stabilizes temperature for high-accuracy results. This method is ideal for hard or exotic metals such as stainless steel, nickel alloys, tool steel, titanium, and carbide. With full CNC control along X and Y axes, Wire EDM enables tight tolerances, high repeatability, and consistent surface quality for prototypes, small-batch runs, or high-volume production. Our experienced team works directly with your designs to ensure every part meets your exact precision, tolerance, and performance requirements, making Wire EDM a reliable choice for demanding aerospace, medical, and industrial applications. Learn more about our CNC machining capabilities for a complete precision manufacturing solution.
Limitations Of Wire EDM
- Conductive Materials Only – Wire EDM can only machine electrically conductive materials, such as metals and certain alloys.
- Slower Cutting Speed – Compared with conventional CNC machining, laser cutting, or waterjet cutting, wire EDM is generally slower for simple parts.
- Recast Layer Formation – A thin heat-affected or recast layer may form along the cut edge and sometimes requires secondary finishing.
- Specialized Setup Required – Achieving optimal results often requires experienced operators and precise programming.
Advantages Of Wire EDM
- No Mechanical Cutting Forces – The non-contact EDM process reduces burrs, distortion, and deformation, making it ideal for delicate parts.
- Ideal for Hard Materials – Efficiently cuts hardened tool steel, titanium, Inconel, and other difficult-to-machine conductive alloys.
- Excellent Surface Finish – Multi-pass wire EDM cutting can produce smooth surfaces with minimal secondary finishing.
- Perfect for Thin Walls & Narrow Slots – Suitable for thin sections, complex contours, and fragile components.
- No Custom Tooling Required – CNC-controlled cutting enables quick setup and shorter lead times for prototypes and production.
Wire EDM Applications
Wire EDM machining is ideal for metal components requiring full-thickness cuts, intricate tolerances, and minimal material stress or heat impact, making it perfect for materials that are too brittle for conventional stamping. This precise cutting method is widely used across industries, including medical devices, aerospace and military equipment, automotive components, electronics, robotics, and precision tooling such as extrusion dies, cutting tools, and matched metal tooling. Our experienced engineers and machinists leverage deep knowledge of EDM machining practices and material behavior to ensure each part meets strict specifications while optimizing production efficiency and minimizing costs. By collaborating closely with clients during pre-production reviews, we ensure that every wire EDM project—from prototype to high-volume production—delivers consistent, high-quality, and reliable results for demanding industrial applications worldwide.
Other CNC Machining Services
Request Your Free CNC Machining Quote Today
After receiving your drawings, our engineers will analyze your custom CNC machining parts right away. We actively work with you to clarify all details before providing a quote that is both economical and accurate.