Aerospace

Provide efficient production and faster design to delivery.

Automotive

Produce precision parts that exceed industry standards.

Automation

Create and test products quickly to bring them to market.

Consumer Products

Bring new, affordable products to market faster.

Communication

Empower to innovate faster, maximizing performance.

Electronics

Innovation in enclosures for low-volume production.

Industrial Equipment

Deliver machinery that beats the competition.

New Energy

Speed up innovation and development.

Medical Devices

Build prototypes and products that adhere to medical safety.

Robotics

Improve efficiency with precise, fast, and constant part quality.

Semiconductor

Drive time-to-market through on-demand production.

CNC Machining for Aerospace

The extremely high level of precision needed within the aerospace industry makes CNC machining a suitable manufacturing process for the sector.

 

This article provides you with a complete guide to aerospace machining and its importance.

 

Blog

Gain valuable insights into manufacturing processes.

Materials

Choose from 50+ metals and plastics for your project.

Case Studies

Learn successful stories to inspire your project.

Knowledge Base

Whitepaper, design guide, materials, and finishing.

Surface Finishes

Different finishing options enhance part appearance and functionality.

Videos

Discover our library of educational videos.

CNC Machining eBook

If you want to produce high-quality machined parts with a sleek appearance, it’s essential to consider some critical factors related to CNC machining. 

 

Here, we’ve gathered some basic information and important considerations to help you achieve the desired results.

About RapidDirect

Our vision, mission, development history, and dedicated team.

Testimonials

Real feedback on experiences and opinions of our services.

News

Company news, platform updates, holiday announcement.

Our Platform

Get instant quotes with our smart online platform.

Our Capabilities

Rapid prototyping, and on-demand production.

Quality Assurance

Deliver quality parts that meet requirements and exceed expectations.

Contact Us

Online Quotation Platform v3.0

Attention! We have exciting news to share with you. We have just launched the latest online platform, version 3.0! 

 

 

The updated platform boasts a fresh and intuitive design, along with enhanced functionality that streamlines and accelerates the quoting process, like a new manufacturing process, streamlined quoting summary page, and improved checkout page. 

Wire EDM Services

Get precision machined parts with our advanced cutting solutions, perfect for complex geometries.

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Wire EDM (Electrical Discharge Machining) stands out as a subtractive manufacturing marvel. It’s a technique where electrical sparks shape and carve through conductive materials. What sets Wire EDM apart? Its unmatched precision. Using a fine electrically charged wire—often brass or copper—guided by advanced CNC systems, the process meticulously erodes materials, achieving intricate and accurate designs.

However, mastering Wire EDM isn’t simple. It demands expertise to ensure consistent, high quality results. That’s where RapidDirect steps in. Drawing upon years of experience and innovation, we harness Wire EDM’s full potential, transforming complex designs into tangible, high-quality products. But we don’t stop at just delivering what the market expects. At RapidDirect, we’re on a mission: pushing the boundaries, setting new benchmarks in precision machining, and, most importantly, ensuring our clients receive the unparalleled solutions they deserve.

Why Choose Our Wire EDM Service

When it comes to precision manufacturing, Wire EDM stands out as a process that offers high accuracy and intricate detailing. For businesses seeking the best in Wire EDM services, RapidDirect is the go-to choice.

1Late Prototyping Stage

State-of-the-Art Technology

RapidDirect uses top-tier, regularly updated machinery, ensuring clients receive workpieces machined to the highest standards of precision and accuracy.

1Support

Expertise and Experience

With years of experience, our specialists onsistently deliver products that surpass client expectations, reflecting our mastery in manufacturing intricacies.

1Die casting Rapid Quotation

Online Ordering and Quoting

RapidDirect's online platform offers instant quotes and real-time order tracking. Streamline your projects with our efficient, transparent system for maximum convenience in the digital age.

1Efficiency

Quick Turnaround Times

In our fast-paced world, RapidDirect ensures quick project turnarounds without compromising on quality, thanks to our efficient processes and dedicated team.

Wire EDM for Prototyping & Production

RapidDirect is a comprehensive all-in-one manufacturing platform designed for all the needs of your Wire EDM projects.

cnc machining

Rapid Prototyping

At RapidDirect we understand the importance of speed and accuracy in the prototyping phase. Our Wire EDM services empower you to bring your concepts to life in the shortest possible time.

Capability: 20-500

Lead Time: 10 business days

Low-volume Manufacturing of cnc machined part

Low Volume Manufacturing

We specialize in delivering low-volume manufacturing solutions that ensure your parts are meticulously crafted with consistency and precision throughout every piece.

Capacity: 500-1000

Lead Time: 15 business days

secondary processing of plastic injection molding

High Volume Manufacturing

RapidDirect consistently delivers top-quality results, from single prototypes to large product batches, without compromising reliability.

Capacity: 1000+

Lead Time: 20 business days

Wire EDM Part Size Standards

Parameter Small Parts (mm) Medium Parts (mm)Large Parts (mm)
Maximum Length 50100500
Maximum Width 3070300
Maximum Height 1040150
Minimum Thickness0.51.05.0
Tolerance±0.005±0.01 ±0.03

Metals for Wire EDM

Our experts at RapidDirect have pride in their capability to work with a wide range of materials that can open up a world of possibilities for your projects. A few of the materials can handle are:

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  • Aluminum
  • Copper
  • Brass
  • Steel
  • Titanium
  • Bronze
  • Other Conductive Materials
P02 2 S06 Aluminum 1

Aluminum

A popular choice in industries seeking lightweight yet durable components. We can precisely cut and shape aluminum parts for aerospace, automotive, electronics, and more.

copper

Copper

Copper’s excellent electrical and thermal conductivity makes it indispensable for electrical components, connectors, and conductive elements. Our expertise ensures that copper parts are crafted with utmost precision to ensure that the resulting parts maintain their core properties.

CNC machining brass

Brass

With its appealing aesthetic and excellent machinability, brass finds applications in decorative components, electronics, and plumbing fittings. Our Wire EDM process guarantees intricate and accurate brass parts in the shortest lead time.

P02 2 S06 Stainless steel 1

Steel

From tool steels to stainless steels, our Wire EDM services can handle a variety of steel alloys. We deliver precise and consistent results and fulfill the requirements of industries like automotive, tool and die, and precision engineering.

P02 2 S06 Titanium 1

Titanium

As a challenging material to machine, titanium requires a specialized approach for optimal results. Our Wire EDM expertise allows us to tackle titanium components with the highest level of precision. Thereby making it an excellent choice for aerospace, medical, and performance engineering applications.

copper

Bronze

Bronze is valued for its unique combination of strength and corrosion resistance, making it suitable for bearings, gears, and artistic applications. Since Bronze is expensive, any waste can have a significant impact on the cost. Our Wire EDM technology ensures excellent results with minimal waste along with the shortest turnaround time.

P02 2 S06 PA 1

Other Conductive Materials

Our Wire EDM capabilities extend beyond the common materials. We are proficient in working with precious metals like gold and silver, as well as various nickel alloys. Whatever your specific material requirements, we have the expertise to deliver exceptional results.

Surface Finishing for Wire EDM

Name Materials Color Texture Link
Anodizing Aluminum Clear, black, grey, red, blue, gold. Smooth, matte finish. Learn More>>

Bead Blasting

ABS, Aluminum, Brass, Stainless Steel, Steel

n/a Matte Learn More>>
Powder Coating Aluminum, Stainless Steel, Steel

Black, any RAL code or Pantone number

 Gloss or semi-gloss

Electroplating

Aluminum, steel, stainless steel

n/a

Smooth, glossy finish

Polishing

Aluminum, Brass, Stainless Steel, Steel

 n/a

Glossy

Brushing

ABS, Aluminum, Brass, Stainless Steel, Steel

n/a satin

Applications of Wire EDM Machined Parts

automotive parts
automotive metal parts

Global experience that counts. Our committed team at RapidDirect has the right skills and expertise to fulfill various industrial requirements. Some of the industries that we work with are:

Wire EDM Process

It’s important to remember that Wire EDM is an erosion process as opposed to other subtractive processes that rely on cutting. So, it has different surface properties that often rely on the number of passes (iterative cuts) for the optimum level of finish. Here’s how we go about it.

First Pass (Rough Cut)

A rougher finish to quickly achieve the design with a tolerance of +/- .002’. About 90% of wire EDM parts only need the first pass as the tolerance is acceptable for a lot of applications and surface finishing requirements.

Second Pass (Finishing Cut)

For more advanced applications, a second pass with more refinement can achieve tolerances of up to +/- 0.0005” along with a surface finish of 72 µin, which is almost indiscernible to the eye.

Third Pass (More Granular Details)

This is the most refined cut with the finest finish that is needed for highly sensitive applications like medical devices and aerospace components. The third pass can bring the surface finish down to 35 µin, which is more than needed for many wire EDM applications.

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Frequently Asked Questions

Yes, Wire EDM is capable of machining hard materials effectively. Its non-contact process, which uses electrical discharges to erode the material and allows it to work with materials that are difficult to machine using conventional methods.

 

Materials like hardened steels, tool steels, titanium, and carbide can be precisely machined using Wire EDM. This makes it a preferred choice for industries requiring high hardness and wear resistance.

Wire EDM is renowned for its exceptional precision and accuracy. It can achieve tolerances as tight as ±0.0001 inches (0.0025 mm). Thereby ensuring consistent and repeatable results.

 

The process is capable of producing intricate and delicate features with superior surface finishes which makes it ideal for applications where precision is critical.

Wire EDM can create a wide range of shapes and geometries, limited only by the imagination and complexity of the designs.

 

It excels at producing intricate contours, sharp corners, small holes, and complex 3D shapes. Whether it’s internal features, external profiles, or unconventional shapes, Wire EDM can accurately cut and shape them with ease.

While Wire EDM offers many advantages, it does have some limitations. One of the main limitations is the requirement for materials to be conductive, as the process relies on electrical discharges. Additionally, the cutting speed of Wire EDM is slower compared to some traditional machining methods, which can impact production time for large quantities.

 

Furthermore, the initial setup and programming can be time-consuming for complex parts, but this is offset by the high precision and efficiency achieved during the actual machining process.

Wire EDM is primarily designed for the precision cutting of thin to moderate-thickness materials. While it can handle materials up to several inches thick, cutting very thick materials becomes challenging and time-consuming due to the slower cutting speeds and the need for multiple passes.