What is Electrical Discharge Machining (EDM)?

A non-contact precision machining process used for aerospace, defense, and medical components requiring tight tolerances and complex geometries.

Electrical Discharge Machining (EDM) removes material using controlled electrical discharges (sparks) rather than mechanical force. This enables precision machining of hardened metals, exotic alloys, and intricate geometries that are difficult or impossible with traditional methods.

During EDM machining, the electrode and workpiece are submerged in a dielectric fluid. A CNC-controlled system maintains a precise gap while electrical discharges occur. These controlled sparks remove material through localized melting and vaporization.
Because there is no physical contact, EDM eliminates mechanical stress and distortion while maintaining exceptional dimensional accuracy and surface integrity.

EDM Processes

Wire EDM: Precision cutting using a fine wire electrode

Sinker EDM: Complex cavity machining using formed electrodes

Small Hole EDM: High-precision micro drilling for aerospace applications

Advantages

EDM enables machining of hardened and exotic materials without mechanical stress or distortion while maintaining extremely tight tolerances. It is ideal for complex geometries, thin-walled components, and high-repeatability production.

Why Use EDM?

• Machines thin walls, complex geometry, narrow slots, and micro-features with no mechanical stress.

• Cuts hardened steel, titanium, Inconel, and exotic alloys without tool limitations.

• Produces burr-free surface finishes directly from the machine.

• Reduces cost through stacked machining and multi-up fixturing.

• Replaces broaching with higher precision and no tooling risk.

• Replaces stamping for sharp corners and reduced tooling cost.

• EDM is ideal when traditional machining fails due to hardness, geometry, or stress sensitivity.

• It enables tight tolerances, complex geometry, and high-quality finishes in a single controlled process without mechanical force.

EDM Machining Capabilities

Wire EDM Sinker EDM Hole Pop EDM
Max. Material Thickness 20″ (508 mm) 12″ (304.8 mm) 12″ (304.8 mm)
Max. Part Length 36″ (914.4 mm) 24″ (609.6 mm) 36″ (914.4 mm)
Max. Part Width 24″ (609.6 mm) 14″ (355.6 mm) 24″ (609.6 mm)
Taper Angle 45° — —
Min. Internal Corner Radius .0025″ (.064 mm) .001″ (.025 mm) —
Wire/Electrode Diameter .004″–.012″ — .010″–.125″
Wire/Electrode Materials Brass
Copper
Zinc-coated		 Graphite
Copper-impregnated
Copper Tungsten		 Brass
Copper
Tungsten
Tolerances (+/-) +/-.0001″ +/-.0002″ +/-.0015″ (locational)
Equipment Capabilities Auto-threading
Unattended run
Five-axis CNC
Stacked parts machining
Temperature control		 Four-axis CNC
Multi-up fixtures & electrodes
Temperature control		 Fully programmable CNC

Why Choose New Jersey Precision Technologies?

• Specialists in Wire, Sinker, and Small Hole EDM

• Aerospace, defense, and medical industry experience

• Machining of hardened and exotic materials

• High repeatability and tight-tolerance production

New Jersey Precision Technologies delivers advanced EDM solutions engineered for high-reliability industries where precision is critical.

From prototype development through production runs, we ensure accuracy, consistency, and quality in every component we manufacture.

We welcome the opportunity to discuss your machining needs. Please contact New Jersey Precision Technologies by phone at 1.800.409.3000, fax at 1.800.409.3022 or email at sales@njpt.com.

Visit our introductory pages for Wire EDM, Small Hole EDM and Sinker EDM more information on the EDM process.