Wire EDM at HAILTEC
Precision and innovation in spark erosion
The wire EDM is a high-precision manufacturing process that plays a central role in HAILTEC's range of services. Spark erosion Even the hardest materials can be cut with the highest precision and complex geometries can be realized. As an integral part of our Precision manufacturing technologies Wire EDM enables the production of High-precision partsthat operate in demanding industries such as Medical Technology, the Tooling and Aerospace are needed.
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What is wire EDM?
Wire EDM is a form of electrical discharge machining (EDM) in which a thin wire serves as the tool for machining electrically conductive materials. Material is removed by electrical discharges between the wire and the workpiece without any mechanical contact. This process enables highly precise cuts that would be difficult to achieve with other mechanical methods.
Importance of wire EDM at HAILTEC
For HAILTEC, wire EDM is an indispensable tool for manufacturing highly complex components and stamping dies . Thanks to its combination with other manufacturing technologies such as CNC milling , laser cutting , and bending , HAILTEC offers its customers comprehensive manufacturing solutions characterized by precision and efficiency.
The wire EDM process in detail
Wire EDM is based on spark erosion , in which electrical discharges occur between a thin wire (electrode) and the workpiece. These discharges remove material layer by layer without mechanically stressing the workpiece. This allows for the machining of very hard materials such as hardened steel, titanium, or tungsten carbide.
Wires used and their properties
Wire EDM utilizes special brass or coated wires . These wires are extremely thin, with diameters between 0,1 mm and 0,3 mm, and possess high electrical conductivity to ensure precise cuts. The choice of wire material depends on the desired machining speed and the required surface finish.
Wire EDM machines at HAILTEC
Specifications and capabilities
HAILTEC relies on state-of-the-art wire EDM machines (start hole EDM machines) from renowned manufacturers, equipped with highly developed controls and innovative technologies.
Working area and maximum workpiece sizes
The working area of our wire EDM machines allows for the machining of workpieces with dimensions of up to 400 x 300 x 220 mm . This enables us to manufacture both small, delicate precision parts and larger tools and fixtures.
Advantages of our cleanroom service
Our ISO 7 cleanroom service offers you numerous benefits that are crucial for medical technology and other industries:
High precision and surface finish
Wire EDM enables cuts with tolerances in the micrometer range and excellent surface quality without the need for rework.
Machining of the hardest materials
Even extremely hard materials such as tungsten carbide, hardened steel and titanium can be machined effortlessly.
Complex geometries and internal contours
Wire EDM can also be used to create very fine and complex geometries, including sharp internal angles and extremely thin structures.
Burr-free cuts
Since the process is non-contact, no mechanical stresses or burrs are created, which minimizes post-processing.
Application areas of wire EDM at HAILTEC
With its expertise in wire EDM, HAILTEC serves a wide range of industries where precision and material diversity play a major role.
Industries
- Tool and mold making: Manufacture of high-precision punching and embossing tools
- Medical technology: Manufacturing of delicate components for medical devices
- Aerospace: Machining of high-performance materials for extreme conditions
Specific parts and components
Typical components that HAILTEC wire-erodes include:
- Precision mechanical components for medical technology
- Punching tools with complex geometries
- Prototypes and small series for the electronics and aviation industries
Combination with other manufacturing processes
At HAILTEC, wire EDM is often used in combination with CNC milling , laser cutting , and bending to produce complex components in a seamless manufacturing process. This integrated manufacturing allows us to offer flexible and cost-effective solutions for demanding projects.
HAILTEC's expertise in wire EDM
Years of experience and specialization
With over 20 years of experience in precision manufacturing , HAILTEC has built up outstanding expertise in wire EDM. Our specialized professionals work with state-of-the-art technology to manufacture highly complex parts with the utmost precision.
Manufacturing highly complex parts
Thanks to our advanced machines and processes, we are able to process even highly complex geometries and the finest structures that would be difficult or impossible to implement using other methods.
Integration into holistic manufacturing solutions
Wire EDM at HAILTEC is part of an integrated manufacturing process that extends from toolmaking to series production . This enables us to develop customized solutions for our customers and implement their projects efficiently and precisely.
Wire EDM and toolmaking at HAILTEC
Manufacture of punching and embossing tools
In toolmaking, wire EDM is a key technology at HAILTEC for the production of high-precision stamping and embossing tools. These tools are used for the series production of complex sheet metal and metal parts.
Manufacture of special devices
In addition to stamping tools, HAILTEC also manufactures custom fixtures and special tools precisely tailored to our customers' requirements. The high precision of wire EDM enables the production of even these demanding components with tight tolerances.
Advantages of in-house tool production
By manufacturing its own tools, HAILTEC can respond flexibly to customer requirements and make adjustments quickly, resulting in shorter lead times and higher cost efficiency.
Quality assurance in wire EDM
Measurement and testing technologies used
HAILTEC uses state-of-the-art optical and tactile measuring systems to verify the precision of manufactured parts during and after the wire EDM process. These measuring systems make it possible to maintain tolerances in the micrometer range with absolute accuracy.
Quality management and certifications
Our quality management system is certified according to ISO 9001 and ISO 13485 , which guarantees the highest standards in production, especially in medical technology and other safety-critical industries.
Combination of wire EDM with other technologies
At HAILTEC, wire EDM is often combined with other manufacturing processes to produce hybrid components . For example, wire-eroded workpieces can subsequently be milled or laser-machined to integrate additional functions. These integrated manufacturing processes enable us to efficiently produce complex components and offer our customers customized solutions.
Programming and CAD/CAM systems in wire EDM
Software and systems used
HAILTEC utilizes advanced CAD/CAM systems that enable precise programming of wire EDM machines. These software solutions offer interfaces for simulating and predicting machining results , thus increasing process reliability.
Optimization of cutting strategies
By simulating cutting strategies, we can optimize material consumption and minimize processing times. This ensures efficient production and consistently high quality.
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FAQ about wire EDM at HAILTEC
Which materials can be wire-cut at HAILTEC?
We machine a wide variety of materials, including hardened steel, titanium, tungsten carbide, and copper alloys.
How precise is wire EDM at HAILTEC?
Our machines achieve a precision of ±1-5 micrometers , ideal for high-precision applications.
What advantages does wire EDM offer over other cutting processes?
Wire EDM enables burr-free cuts, processes the hardest materials and realizes complex geometries with the highest precision.
What is the maximum size of the workpieces when wire EDMing?
We process workpieces with dimensions of up to 400 x 300 x 200 mm.
Can HAILTEC also wire-cut small series or individual pieces?
Yes, we manufacture prototypes and individual pieces as well as series production.
How does HAILTEC combine wire EDM with other manufacturing technologies?
Wire EDM is often combined with milling , laser cutting or bending in our process to manufacture complex components efficiently.
Which industries particularly benefit from HAILTEC’s expertise in wire EDM?
In particular, medical technology , toolmaking and aerospace benefit from our high-precision manufacturing solutions.