Wire erosion at HAILTEC
Precision and innovation in spark erosion
The wire eroding is a high-precision manufacturing process that plays a central role in HAILTEC's range of services. With the help of 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 erosion enables the production of high-precision high-precision partswhich are used in demanding industries such as medical technologythe toolmaking and the aerospace are required.
Many well-known customers from industry
already rely on our expertise
What is wire EDM?
The wire erosion is a spark erosion process in which a thin wire is used as a tool to machine electrically conductive materials. Electrical discharges between the wire and the workpiece remove material without mechanical contact. This process makes it possible to carry out high-precision cuts that would be difficult to achieve with other mechanical processes.
Importance of wire EDM at HAILTEC
For HAILTEC, wire erosion is an indispensable tool for the production of highly complex components and stamping tools. Thanks to the combination with other manufacturing technologies such as CNC milling, laser cutting and bending HAILTEC offers its customers comprehensive manufacturing solutions that are characterized by precision and efficiency.
The wire EDM process in detail
Wire erosion is based on the spark erosionin which electrical discharges take place between a thin wire (electrode) and the workpiece. These discharges remove material layer by layer without mechanically stressing the workpiece. This enables the machining of very hard materials such as hardened steel, titanium or tungsten carbide.
Wires used and their properties
Special brass wires are used for brass wires or coated wires are used. These wires are extremely thin, with diameters between 0.1 mm and 0.3 mm, and have high electrical conductivity to ensure precise cuts. The choice of wire material depends on the desired processing speed and the required surface finish.
Wire EDM machines at HAILTEC
Specifications and capabilities
HAILTEC relies on the most modern wire erosion machines (start hole erosion machine) from renowned manufacturers, which are equipped with highly developed controls and innovative technologies.
Working range and maximum workpiece sizes
The working range of our wire EDM machines enables the machining of workpieces with dimensions of up to 400 x 300 x 220 mm. This allows us to produce small, delicate precision parts as well as larger tools and fixtures.
Advantages of wire EDM
Wire EDM offers many advantages over other cutting processes such as milling or laser cutting:
Areas of application for wire EDM at HAILTEC
With its expertise in wire EDM, HAILTEC serves a wide range of industries in which precision and material diversity play a major role.
Industries
- Tool and mold making: production of high-precision stamping and embossing tools
- Medical technology: production of filigree components for medical devices
- Aerospace: processing high-performance materials for extreme conditions
Specific parts and components
Typical components that HAILTEC wire EDMs include:
- Precision mechanical components for medical technology
- Punching tools with complex geometries
- Prototypes and small series for the electronics and aviation industry
Combination with other manufacturing processes
Wire EDM at HAILTEC is often used in combination with CNC milling, laser cutting and bending are used to realize complex components in a continuous manufacturing process. This integrated production allows us to offer flexible and cost-efficient solutions for demanding projects.
HAILTEC's expertise in wire erosion
Years of experience and specialization
With over 20 years of experience in precision manufacturing HAILTEC has built up outstanding expertise in the field of wire EDM. Our specialized specialists work with the latest technology to produce highly complex parts with the highest precision.
Production of highly complex parts
Thanks to our advanced machines and processes, we are able to produce even highly complex geometries and finest structures that would be difficult or impossible to realize with other processes.
Integration into holistic manufacturing solutions
Wire EDM at HAILTEC is part of an integrated manufacturing process that starts with the tool manufacture through to series production production. This enables us to develop customized solutions for our customers and implement their projects efficiently and precisely.
Wire EDM and toolmaking at HAILTEC
Production of punching and embossing tools
In toolmaking wire-cutting is a central technology at HAILTEC for the production of high-precision punching and embossing tools. These tools are used for the series production of complex sheet metal and metal parts.
Production of special devices
In addition to punching tools, HAILTEC also manufactures special devices and special toolswhich are precisely tailored to the requirements of our customers. The high precision of wire EDM makes it possible to manufacture even these demanding components with tight tolerances.
Advantages of in-house tool production
Through the own production of the tools HAILTEC can react flexibly to customer requirements and make adjustments quickly, resulting in shorter throughput times and higher cost efficiency results.
Quality assurance in wire EDM
Measuring and testing technologies used
HAILTEC uses modern optical and tactile measuring systems to check the precision of the manufactured parts during and after the wire EDM process. These measuring systems make it possible to precisely maintain tolerances in the micrometer range.
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 the medical technology and other safety-critical industries.
Combination of wire EDM with other technologies
At HAILTEC, wire erosion is often combined with other manufacturing processes combined to produce hybrid components components. For example, wire-cut workpieces can subsequently be milled or laser processed to integrate additional functions. These integrated manufacturing processes enable us to manufacture complex components efficiently and offer our customers tailor-made solutions.
Programming and CAD/CAM systems in wire EDM
Software and systems used
HAILTEC uses advanced CAD/CAM systemswhich enable precise programming of the wire EDM machines. These software solutions offer interfaces for the simulation and prediction of the machining resultswhich increases process reliability.
Optimization of cutting strategies
By simulating cutting strategies, we can reduce material consumption and minimize processing times. This ensures efficient production and consistently high quality.
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FAQ about wire erosion at HAILTEC
Which materials can be wire-cut by HAILTEC?
We machine a wide range 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 micrometersideal for high-precision applications.
What are the advantages of wire EDM compared to other cutting processes?
Wire EDM enables burr-free cuts, processes the hardest materials and realizes complex geometries with maximum precision.
What is the maximum size of the workpieces that can be wire-cut?
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 items 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 to produce complex components in an efficient process.
Which industries particularly benefit from HAILTEC's expertise in wire EDM?
In particular the medical technologythe toolmaking and the aerospace benefit from our high-precision manufacturing solutions.