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Wire EDM / Electrical Discharge Machining

Wire EDM

Bahrs Die & Stamping uses wire cut EDM functions for a wide range of internal applications. Because the wire EDM process can cut very small pieces, it is often an ideal choice for the production of small, highly detailed items that would normally be too delicate for other machining options.

Bahrs Die & Stamping also integrates Wire EDM cutting machines for customer projects that include the production of parts that require extremely hard materials with close tolerances, complex shapes, prototyping, die making, delicate miniature parts and other functions. The wire EDM process is cost effective for low quantity projects, and has proven extremely beneficial in prototype manufacturing, even if the actual project is carried out by different means.

Wire EDM is a unique CNC cutting process that allows us more precision and less waste. Wire EDM is a method to cut conductive materials with a thin electrode that follows a programmed path. The electrode is a thin wire. Typical diameters range from .004″ – .012″ (.10mm – .30mm) although smaller and larger diameters are available. The hardness of the work piece material has no detrimental effect on the cutting speed. There is no physical contact between the wire and the part being machined. Rather, the wire is charged to a voltage very rapidly. This wire is surrounded by deionized water. When the voltage reaches the correct level, a spark jumps the gap and melts a small portion of the work piece. The deionized water cools and flushes away the small particles from the gap.


  • Where deep cutting is required
  • Where EDM finish is specified
  • For hard materials
  • For sharp inside corners
  • For the most complex geometry
  • Where extremely close tolerances are required


  • Intricate & complex details are possible
  • Internal corners down to R .005″ [.125mm]
  • Very high accuracy attainable
  • Precise control of surface finish
  • No cutting forces
  • Virtually no geometric limitations

Wire EDM can be accurate to +/-.0001″. Virtually no burrs are generated. Since no cutting forces are present, wire EDM is ideal for delicate parts. No tooling is required so delivery times are short. Tools and parts are machined after heat treatment, so dimensional accuracy is held and not affected by heat treat distortion.

Wire EDM can be used for a multitude of industries, such as:

  • Aerospace
  • Electronics & Other High-Tech Industries
  • Manufacturing
  • Energy
  • Die/Mold
  • Medical
  • Automotive
  • Micro Machining

Wire EDM cutting can be used with a wide range of materials. Wire EDM works on parts resistant to conventional machining processes, but only if these parts are electrically conductive; usually, they are non-ferrous, and include steel, titanium, super alloys, brass, and many other metals. Instead of cutting the material, wire EDM melts or vaporizes it, leaving little debris and providing a very accurate line. Industry-wide acceptance has led to a wide variety of wire EDM applications, as it is highly versatile, can cut hard metals, and utilizes a relatively compact amount of workspace.

The newest Bahrs’ Wire EDM machine is a Sodick linear motor driven type that features a direct-drive, non-contact, vibration-free mechanism for unrivaled acceleration and positioning accuracy with no backlash.  The manufacturer stands behind their positioning accuracy with a 10-year guarantee, so you can be assured of the accuracy of your Wire EDM machining done by Bahrs.  This equipment gives Bahrs Die & Stamping the ability to perform Wire EDM with a sense of security knowing we will not lose any accuracy over the years.  The positioning accuracy is monitored by glass scales, which are the most accurate form of position measurement available.

Bahrs’ Wire EDM machine has an annealing function that heats, stretches to a pointed end and cuts the wire. This advanced feature ensures a higher success rate in threading wire through a hole on a submerged workpiece or on a small diameter hole, which saves Bahrs time and allows us to meet very aggressive Wire EDM project deadlines.

Wire EDM cutting is a machining service that differentiates Bahrs by providing us with a unique capability. From prototype parts to low- and high-volume production runs, Bahrs Die & Stamping is the EDM company you can rely on for all your wire cut EDM manufacturing needs.

Contact us today to see how we can meet all your Wire EDM needs.