Wire EDM to tolerances
no mill can touch.

Every submitted print receives a full Design for Manufacturability review. We flag undercut geometry, re-entrant features, and tolerance stack-ups before quoting. No surprises on the shop floor. Quotes include material cost, wire passes required, expected surface finish Ra, and estimated run time per piece.

CAM programs are generated from your native geometry — no redraws, no interpretation. Wire offset, skim pass count, and taper angles are set per material grade. Toolpath simulation confirms no wire collisions before machine time is committed. Complex contours with multiple interior features are nested for material efficiency.

Wire diameter is selected based on minimum inside corner radius requirements and surface finish targets. Standard brass wire (.010") handles most D2 and A2 work. Fine wire (.004"–.006") is used for micro-features and carbide inserts. Dielectric conductivity is verified and conditioned per material type — carbide, titanium, and Inconel each require different flush pressures and spark energies.

Parts are fixtured on precision-ground tooling plates. Datum features are indicated to within .0001" before the program starts. For tall workpieces, taper angle is verified with a certified test piece. Machines run submerged for maximum thermal stability on tight-tolerance work. Operator checks first pierce location against CAM simulation before full program release.

First articles are measured on a temperature-controlled CMM. All dimensions called out on the print are reported — no selective ballooning. Surface finish is measured at representative locations per call-out. AS9100 first article reports are generated automatically and included with the shipment. FAI approval gates the production run; no parts ship without a passed first article.

Production runs use the validated first-article program without modification. In-process inspection checkpoints are set at 10-piece intervals for short runs, 25-piece for production quantities. Wire breaks trigger automatic re-thread and program resume — no operator intervention required for most alloys. Statistical process control data can be provided for aerospace customers requiring Cpk reporting.

Parts are cleaned ultrasonically, inspected under magnification, and individually packed in VCI poly bags with foam support for complex geometries. Certificate of Conformance, FAIR report, and CMM data sheet ship with every order. AS9100 traceability records are retained for 10 years. Expedite options available — call before submitting print for current machine availability.