Wire EDM machining

Overview

Precise cuts with no cutting force

Wire EDM cuts conductive metal with a thin, electrically charged wire. Tiny sparks erode the material instead of a tool pushing against it, so there is no cutting force on the part. That lets us machine delicate features, sharp inside corners and complex profiles that would distort under a milling cutter.

Because the process does not care how hard the metal is, Wire EDM is ideal for hardened and heat-treated materials that are difficult to machine any other way. The narrow cut removes very little material, so waste is minimal and accuracy is high. Star Precision uses Wire EDM on its own or alongside milling and turning to finish the toughest features on a part.

When Wire EDM is the right tool

Bring us a part with fine detail, sharp corners or hard material and we will tell you exactly how we would cut it. Wire EDM solves the features that other processes struggle with.

• Fine detail and sharp cornersNarrow wire cuts intricate profiles and tight inside radii.
• Hardened materialsCuts hard and heat-treated metals that are difficult to machine.
• High accuracyNo cutting force means no distortion, so the part stays true.
• Minimal wasteThe narrow cut removes very little material from the part.

Materials we cut

We cut a wide range of conductive metals, including hardened and heat-treated alloys other processes struggle with, and will help you choose the most cost-effective option during quoting and DFM review. Not sure if your material qualifies? Tell us the alloy and hardness and we will confirm it.

• Mild & carbon steelOur workhorse metal for brackets, dies and general structural parts.
• Stainless steelResists rust and stands up to harsh, wet and sterile conditions.
• AluminumLightweight yet rigid, cuts cleanly to a fine finish.
• Copper & brassConduct electricity well and finish cleanly for connectors and fittings.
• Hardened & heat-treated alloysWire EDM does not care how hard the metal is, so tool steels and hardened parts cut just as cleanly.

Wire EDM specifications

Our two Fanuc ROBOCUT wire EDM machines, a C400iA and a C600iA, handle small, precise profiles up through larger, heavier workpieces, verified by automated CMM inspection. Bring us a challenging profile or a hardened part and we will tell you exactly how we would cut it.

Our Wire EDM process

Every job follows the same controlled path, from first quote to final inspection, so parts come off the machine accurate, repeatable and ready for the next step whether you order one part or ten thousand.

1. Quote & DFM reviewSend a drawing or CAD model. We review it for manufacturability, flag any changes that would lower cost or improve tolerance, and quote fast.
2. Program the pathIndustry-best CAD generates the wire path straight from your data, reducing programming time before the wire ever threads through the part.
3. Wire EDM cuttingA charged wire on one of our two Fanuc ROBOCUT machines erodes the profile with no cutting force, holding fine detail even in hardened metal.
4. CMM inspectionAutomated CMM inspection confirms the profile and critical features meet tolerance before the part moves on.
5. Clean & finishParts are cleaned and prepared for any secondary finishing, plating or coating you require.
6. Assemble or shipFinished parts move straight into milling, turning or assembly under one roof, or are packaged and shipped direct to you.

Wire EDM inside a one-stop shop

Wire EDM does not have to stand alone. It works alongside milling, turning, fabrication, finishing and full electro-mechanical assembly, so you order a finished, inspected product from a single Texas supplier.

• Milling & turningEDM-cut features combine with milled and turned features on the same part, in the same shop.
• Coating & finishingWe coordinate powder coat, plating and anodizing so parts arrive fully finished.
• Assembly & box buildFinished components are built into electro-mechanical sub-assemblies, all under one roof.

Industries we serve

Star Precision cuts fine-detail, close-tolerance parts for demanding Texas and national manufacturers, including the regulated and heavy-industrial sectors below, where certified quality and material traceability matter as much as the part itself:

• Aerospace & spaceWe cut complex, close-tolerance profiles for aerospace and space hardware.
• Defense & militaryWe cut ruggedized, tightly controlled components to demanding defense specifications.
• Medical & scientificWe cut precise, repeatable parts for laboratory instruments and medical devices.
• Oil, gas & energyWe cut durable, corrosion-resistant parts for power and energy equipment.
• Industrial & OEMWe cut dies, fixtures and production components for industrial and OEM manufacturers.

What to expect when you work with us

Working with a machine shop should be straightforward. From the first file you send to the finished parts arriving on your dock, here is what you can count on from our team.

• Send a profile or a sampleA STEP, IGES, DXF/DWG or PDF file works, or send the hardened part you need cut and we will program the wire path from it.
• Fast, honest quotesWe confirm your profile and material fit our EDM envelope, then quote fast, no guesswork on hardened features.
• One point of contactOne team owns your job from cutting through finishing and assembly, all under one roof.
• NDAs on requestWe sign NDAs on request, so your die and tooling designs stay fully confidential.
• On-time deliveryYou get dependable, on-time delivery from our Texas shop, not an overseas queue.

Wire EDM FAQs

Quick answers about our Wire EDM services. Company-wide questions are covered in the FAQs at the bottom of the page.

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