Wire EDM Services

Process Principle & Advantages

Wire EDM removes material through controlled electrical discharges between a continuously fed brass wire and the workpiece — no physical contact, no cutting force. Each spark erodes a minute amount of material, and tens of thousands of sparks per second produce precise, repeatable cuts through any electrically conductive material regardless of hardness. For tight-tolerance profiles, intricate slots, and through-features in hardened components where milling would cause distortion or simply cannot reach, wire EDM is the correct process.

Advantages of Choosing Keywin Wire EDM Services

High Precision Manufacturing

Advanced Wire EDM technology enables accurate machining of complex parts with excellent repeatability.

No Cutting Force & Minimal Deformation

The non-contact EDM process reduces mechanical stress and helps maintain part accuracy.

Complex Geometry Capability

Suitable for thin walls, small radii, narrow slots, and complicated profiles.

Flexible Production Options

Support rapid prototypes, engineering samples, and production quantities.

Integrated CNC Manufacturing Support

Combine Wire EDM with CNC machining, surface finishing, and inspection services for complete manufacturing solutions.

Machining Capabilities & Equipment

Wire EDM Accuracy

±0.003 mm standard | ±0.002 mm achievable on stable geometry
Wire Diameter

Ø0.1 – 0.3 mm (standard Ø0.25 mm brass wire)
Surface Roughness

Ra 0.4 – 2.0 μm (finish cut); Ra 0.2 μm (mirror cut available)
Typical Lead Time

Samples: 2–5 days | Production: 7–15 days

CNC Milling Factory

Established	2000
Number of Machines	70+
Location	Zhongshan

CNC Turning Factory

Established	2000
Number of Machines	30+
Location	Zhongshan

Die Casting Factory

Established	2010
Number of Machines	10+
Location	Zhongshan

Injection Molding Factory

Established	2008
Number of Machines	20+
Location	Zhongshan

Forging Factory

Established	2014
Number of Machines	10+
Location	Zhongshan

Machinable Materials

EDM machines any electrically conductive material — hardness is not a limiting factor:

Metals & Alloys

Material	Features	Common Grades
Tool & Die Steel	High hardness (58–65 HRC), wear-resistant, heat-treatable — retains sharp edges and dimensional stability under repeated impact and pressure.	D2, H13, SKD11, P20, S136
Hardened Alloy Steel	Through-hardenable, high tensile strength, good fatigue resistance — maintains mechanical properties under sustained load and cyclic stress.	4140, 4340, 52100
Stainless Steel	Corrosion-resistant, non-magnetic options available, good surface finish compatibility — suitable for food, medical, and marine environments.	304, 316, 17-4PH, 440C
Copper & Brass	High electrical and thermal conductivity, good corrosion resistance, excellent machinability — standard for conductive and fluid-handling components.	T2, H62, beryllium copper
Inconel	Retains strength at high temperature (up to 1,090°C), oxidation and corrosion resistant — the standard for extreme thermal and chemical environments.	Inconel 718

Applications of Wire EDM Machining

Mold & Die Industry

Injection mold components
Punches and dies
Precision inserts

Automotive Industry

Automotive precision parts
Tooling components
Prototype components

Medical Industry

Surgical components
Medical device parts

Automation & Machinery

Fixtures
Precision mechanical parts
Custom components

Wire EDM vs. CNC Milling

Wire EDM and CNC milling are both precision machining methods used for manufacturing complex metal parts. However, they use different cutting principles and are suitable for different applications.

Wire EDM uses electrical discharge energy to cut electrically conductive materials without direct tool contact, making it ideal for hardened materials, intricate profiles, and tight-tolerance components.

CNC milling uses rotating cutting tools to remove material mechanically, offering high efficiency for general machining, 3D shapes, pockets, holes, and larger production requirements.

Choosing between Wire EDM and CNC milling depends on factors such as material hardness, part geometry, tolerance requirements, surface finish, and production volume.

Comparison	Wire EDM	CNC Milling
Machining Method	Electrical discharge cutting using a thin wire electrode	Mechanical cutting using rotating tools
Contact With Workpiece	No direct contact	Direct tool contact
Suitable Materials	Conductive materials such as tool steel, stainless steel, copper, brass, aluminum	Most metals and plastics including aluminum, steel, stainless steel, plastics
Material Hardness	Excellent for hardened materials after heat treatment	Limited by tool hardness and cutting conditions
Accuracy	Extremely high precision for complex parts and tight tolerances	High precision with flexible machining capability
Complex Shapes	Excellent for narrow slots, sharp corners, intricate profiles	Suitable for 3D contours, pockets, holes, and general machining
Cutting Force	Almost no cutting force, reducing deformation risk	Higher cutting force may affect thin or delicate parts
Surface Finish	Excellent surface quality with fine finishing options	Depends on tools, speed, feed rate, and machining conditions
Production Efficiency	Better for complex precision parts	Generally faster for larger material removal
Typical Applications	Dies, molds, precision inserts, punches, medical parts	Machine parts, housings, brackets, prototypes, structural components

Which Machining Method Should You Choose?

Choose Wire EDM Services when your project requires:

● Tight dimensional tolerances
● Complex internal profiles or narrow slots
● Hardened steel or difficult-to-machine conductive materials
● Minimal deformation during machining
● High-precision mold and tooling components

Choose high precision cnc milling when you need:

● Faster material removal
● Large or complex 3D components
● General precision machining
● Higher production efficiency for larger parts

For many precision manufacturing projects, Wire EDM and CNC milling are complementary processes. CNC milling can be used for rough machining and general features, while Wire EDM provides the final high-precision cutting for critical areas requiring tight tolerances.

Keywin provides both precision Wire EDM Services and CNC machining solutions to support prototypes, custom components, and production manufacturing requirements.

Learn More About Our Material

Typical Part Categories

Mold Cavities & Cores

Injection mold, die cast, and stamping tool components

Stamping & Blanking Dies

Punch-and-die sets cut to exact profile tolerances

Precision Gears & Splines

Wire EDM profiles gears and internal splines in hardened steel with uniform tooth-to-tooth accuracy

Tolerance & Quality Control

Our quality system is run by an experienced QC team that tracks each job through four checkpoints: incoming material inspection, first-article confirmation (FAI), in-process sampling, and final outgoing inspection (OQC). Nothing ships without passing all four.
On the measurement side, we run CMM coordinate measurement, hardness testing, surface roughness gauging, and optical projection — and we issue dimensional reports, CMM reports, and full-inspection records on request.
Tolerances are held to ±0.005–0.01 mm across standard CNC work; tighter specs can be discussed at the quoting stage. We also support customer-defined acceptance criteria and can build a custom inspection plan around your drawings.

Why Choose Us

Excellent Service Support
Advanced Equipment & Quality Control
Flexible Machining Capability
Customization & Engineering Support

Excellent Service Support

We run a tight ship from first contact to final delivery — 24-hour quoting, transparent communication, and a dedicated project contact for every order.

24-hour quotation turnaround / rapid prototyping

Rush-order support for time-sensitive projects

Non-conformance resolved with corrective action and re-make at no surprise cost

Advanced Equipment & Quality Control

Our facility carries 100+ precision machines and a full suite of metrology equipment.

100+ machines — annual output exceeding 10 million parts

Precision ±0.005 mm, CMM full inspection on critical features

IQC → FAI → IPQC → OQC — every step documented and traceable

Flexible Machining Capability

Multi-process integration means one supplier for the whole part — machining, finishing, and assembly under one roof.

CNC turning, milling, 5-axis, grinding, EDM, drilling, forging, casting, sheet metal

Component assembly and multi-part coordination supported

Metals, engineering plastics, and composites — 52+ material options

Customization & Engineering Support

OEM and ODM both welcome. We work from drawings, samples, or rough concepts.

DFM analysis and structural improvement suggestions before cutting starts

Custom packaging and surface treatment specified per customer requirement

NDA available — design confidentiality strictly maintained

FAQ

What is EDM machining — and when should I use it instead of CNC?

EDM uses electrical sparks (not cutting tools) to erode material. You should consider EDM when: (1) your material is too hard for conventional cutting — typically HRC 50+; (2) you need sharp internal corners or narrow slots that a rotating cutter can't produce; (3) the feature is fragile or thin-walled and can't tolerate cutting forces. For everything else, CNC milling or turning is usually faster and cheaper.
Can you EDM hardened steel without cracking or distortion?

Yes — that's one of the main reasons people choose EDM. Because there's no cutting force and heat is extremely localized, hardened parts typically don't distort during EDM the way they might under a clamped-down milling operation. The main consideration is the thin recast layer that forms on the cut surface; we can remove it by polishing or lapping if your application requires it.
How accurate is wire EDM — can I use it instead of grinding for tolerance work?

For many applications, yes. Wire EDM holds ±0.003 mm on profile tolerances routinely. For shafts or bores where roundness and surface finish are the priority, cylindrical grinding is usually still the better process. For profiles, die sets, and prismatic features, wire EDM at ±0.003 mm is often more cost-effective than grinding.
What file formats do you need for wire EDM programming?

2D DXF or DWG for wire EDM profiles. 3D STEP or IGES for sinker EDM electrode design. PDF drawings with dimensions and tolerances are required alongside CAD files for all jobs.