Micro Electro Discharge Machining (Micro EDM) removes material through thousands of precisely controlled electrical sparks between a miniature electrode and a conductive workpiece submerged in dielectric fluid. Because there is no mechanical cutting force, Micro Electro Discharge Machining machines features that conventional milling cannot touch: micro holes of 0.05 to 0.5 mm diameter, slots narrower than a human hair, sharp internal corners, and mirror-like finishes on hardened steel above 60 HRC. Our production workflow begins with customer drawings and material certificates, followed by electrode design in graphite, copper tungsten, or tungsten carbide. Incoming lots are verified on CMM and vision systems before machining, with critical dimensions checked every 50 pieces on a coordinate measuring machine and roughness verified by a white-light interferometer. Generator parameters such as pulse on-time, peak current, and gap voltage are tuned per material to balance removal rate against electrode wear, typically keeping wear below 0.2 percent for micro cavities. Applications span injection molds for medical devices, optical lens molds, aerospace turbine blade cooling holes, micro connector dies, and semiconductor lead frames. According to industry studies, Micro EDM holds dimensional capability within plus or minus 0.003 mm and surface roughness as fine as Ra 0.05 micron, metrics that make it the preferred process for dies with ribs under 0.2 mm. Machine platforms combine a granite base, linear motor drives, and a closed-loop gap control system sampling 250,000 times per second. Feature sizes from 30 microns are achievable. Case Title: Proven Micro Electro Discharge Machining Results Across Global Industries
Case Title 1: German Mold Maker Cuts Electrode Wear 42 Percent on Hardened Steel Cavities
Case Description 1: A mold manufacturer in Baden-Wurttemberg, Germany, producing injection molds for automotive connectors, struggled with electrode wear above 0.6 percent and frequent recutting when machining 1.2343 steel at 52 HRC. The shop installed our Micro EDM center with adaptive pulse control and a C-axis rotary spindle, running roughing at 12 A and finishing at 0.5 A. Micro electro discharge machining parameters were tuned per cavity, and dielectric filtration down to 1 micron stabilized flushing. After three months, electrode wear dropped 42 percent, recutting fell by 70 percent, and cavity tolerance held within 0.003 mm across 240 cavities. The customer now runs 22 hours of unattended production daily and reports 15 percent lower tooling cost per mold.
Case Title 2: Japanese Connector Manufacturer Halves Micro-Pin Die Lead Time
Case Description 2: A connector maker near Nagoya, Japan, needed micro-pin dies with 0.15 mm slots for a smartphone component. Wire EDM could not reach the internal geometry, and manual polishing caused dimensional drift. Our Micro EDM system with a 30-micron tungsten electrode machined the slots in a single setup, using a 0.8 microsecond pulse for the finishing pass. Micro electro discharge machining reduced lead time from 18 days to 9 days, surface finish reached Ra 0.08 micron, and pin-to-pin pitch accuracy stayed within 0.004 mm for all 1,200 pins per die. Scrap rate fell from 6 percent to 1.2 percent, saving the customer an estimated USD 46,000 per year.
Case Title 3: US Aerospace Supplier Achieves 0.1 mm Cooling Holes in Turbine Blades
Case Description 3: An aerospace component supplier in Ohio, USA, required 0.1 mm cooling holes at 35 degrees through a nickel superalloy blade wall of 2.5 mm. Laser drilling produced recast layers that failed fatigue testing. Using our five-axis Micro EDM with through-spindle flushing, the holes were drilled at 90 holes per hour with a recast layer under 2 microns. Micro electro discharge machining passed fatigue testing at 100 percent of samples, held hole diameter within plus or minus 0.005 mm, and eliminated secondary deburring. The supplier secured a three-year contract and expanded to four machines within 18 months.
Product Title: Precision Micro Electro Discharge Machining Systems Built for Your Toughest Geometries
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