Service Overview

Sinker and Wire EDM Cutting Service

Wire EDM cutting, also known as electrical discharge machining, is a process that uses an electrically energized thin wire to slice through metal.

Whether you need a single part, batch of prototypes, or full production order, eMachineShop will turn your design into fully machined, end-use parts!

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Wire EDM

can cut most any simple or complex 2D shape including cutouts and thin walls, intricate openings, and sharp inside corners.

This method uses rapid, controlled, repetitive spark discharges from the wire to the workpiece, thereby eroding the metal away. The workpiece must be electrically conductive.


  • High dimensional accuracy for close fitting parts
  • Can make sharp inside corners
  • Cut material thickness from only a few thousandths of an inch to several inches
  • Custom tooling is generally not needed
  • Smooth finishes can be achieved

Design Tips

  • Edges are smooth but matte
  • Typical surface finish is between 16 and 64 microinches
  • The edges of the finished work piece will have virtually no burrs
  • Kerf width typically ranges from 0.001″ to 0.012″
  • Sharp internal corners will be slightly rounded (typically with radius ~.008″)

Wire EDM is a popular choice for many metal products and components:

Auto Parts
Aircraft Parts
Punch and Die Tooling
Stripper Plates
Mold Components
Engine Parts
Handles and Knobs

Example Parts


Metal clamp


Metal clamp

Applications and Advantages

  • Transportation: The combination of lightness, strength and malleability makes aluminum the ideal material for transportation applications. It is used in automobiles, airplanes, railways and marine applications and also for making fuel-efficient engines in cars and trucks. Its low weight reduces fuel consumption and emissions.
  • Construction: Aluminum facilitates the construction of corrosion-resistant and low maintenance cost buildings. All kinds of aluminum products are used for new construction as well as renovation and due to its strength and lightness, it is used in earthquake prone zones. It is also a good reflector of light,and is often used in lighting fixtures.
  • Vehicles: A high proportion of the shock inflicted by an automobile in a motor vehicle accident is absorbed primarily by its aluminum structure.
  • Air Travel: Strong aluminum alloys take the extreme pressures and stresses involved in high altitude flying. Wafer thin aluminum panels keep the cold out and the air in. Many internal fittings like the seating on airplanes are made from aluminum or aluminum composite in order to save weight and thus save fuel, reduce emissions and increase the aircraft’s payload.
  • Packaging and Food Processing: It is non-poisonous, which allows for non-acidic food to be safely wrapped in thin sheets like foil and cooked in vessels. Aluminum cookware is easy to lift, requires considerably less heat than stainless steel or cast iron and utensils heat up quickly and evenly.
  • Electrical Transmission Lines: This very versatile metal can be drawn into thin wires which are often used in products such as light bulbs and telephone wires. Most of the high voltage overhead transmission and distribution lines over long distances are also made of aluminum.


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