Known for precision, Madison, WI, Wire EDM cuts intricate shapes in hard or delicate materials without physical contact. This ability makes wire EDM a cornerstone of Precision CNC Machining and modern production.
At Roberson Machine Company, our wire EDM (Electrical Discharge Machining) technology delivers accurate, burr-free results, from complex prototypes through production-critical assemblies. Connect with our team at 573-646-3996 or contact us online to explore the advantages Madison, WI, Wire EDM brings to your next project.
Article Synopsis
- An overview of how wire EDM works, why it’s a non-contact cutting method, and situations where it beats conventional machining.
- Specifications and capabilities (tolerances, taper angles, work envelopes, materials, etc.) to see if wire EDM cutting matches your project’s strict requirements.
- Illustrative real-world applications and industries such as aerospace, medical, packaging, and energy, and the roles that lead the projects.
- Explaining what Roberson Machine Company brings to the table, with proven workflows, advanced equipment, and dependable turnaround times.
From aerospace prototypes to medical-grade components, wire EDM opens up design and manufacturing possibilities other processes can’t match. Below, we outline how the process functions, where it’s applied, and what working with Roberson Machine Company looks like.
Table of Contents
- What Is Wire EDM Machining?
- Real-World Applications for Wire EDM and Precision Cutting
- FANUC ROBOCUT α-C400iC: New Wire EDM Technology
- Wire EDM Capabilities & Specs
- Who Uses EDM Wire Cutting
- Materials We Work With for Wire EDM
- Why Roberson Machine Company
Learn more about our machining capabilities, success stories and reviews, and other information about Madison, WI, Wire EDM on our blog and FAQs.
What Is Wire EDM Machining? | [city, WI, Precision CNC Services
Wire EDM is a specialized process within our broader CNC machining capabilities. Where traditional tools touch the part, wire EDM cuts conductive materials using a fine, electrically energized wire. The wire produces controlled sparks that erode material along a programmed path, creating extremely accurate cuts with no mechanical stress on the part or component.
For parts and features that defy standard machining—such as intricate profiles, thin slots, sharp internal corners, or hardened alloys like carbide and titanium—wire EDM is the answer. The process produces clean, accurate cuts that are ready for assembly, finishing, or the next stage of production.
Real-World Applications for Madison, WI, Wire EDM and Precision Cutting
When geometry, finish, or tolerance demands are beyond conventional tooling—especially with tough materials, thin walls, or fragile parts—wire EDM is the solution. It handles conductive metals with burr-free precision, including titanium, carbide, Inconel, hardened steels, and more.
Wire EDM serves Madison, WI, teams handling prototypes, fixtures, and production-scale projects. Typical applications include:
- Aerospace: Precision turbine slots, seal details, and tooling inserts that maintain tolerances after heat treating.
- Military & Defense: Hardened alloys and mission assemblies where crisp internal corners and accuracy are vital.
- Automotive: Powertrain tooling, prototype parts, and mold inserts produced with precision internal clearances.
- Medical: Precision implant components, surgical instruments, and micro-scale features cut without burrs.
- Packaging: Wear parts and forming dies with crisp edges and fine finishes to minimize rework.
- Food & Beverage: Corrosion-resistant stainless components for washdown environments, cut without mechanical stress.
- Oil & Energy: Sealing surfaces, pump parts, and alloy components built for high-pressure, corrosive conditions.
- Automation & Robotics: Automation parts such as fixtures, housings, and moving elements cut with tight tolerances.
- Firearm Manufacturing: Slides, internal components, and tooling where repeatable accuracy and clean edges matter.
- Consumer & Commercial Products: Fixtures, branding dies, and precision parts produced for consumer and commercial needs.
- OEM & Custom Applications: Single R&D parts to large production jobs in conductive alloys, even exotic or hardened.
Have a project or a problem? Contact us online or call 573-646-3996 to discuss your Madison, WI, wire EDM machining needs.
FANUC ROBOCUT α-C400iC: New Wire EDM Technology
Our equipment lineup now includes the FANUC ROBOCUT α-C400iC, delivering higher cutting speeds, accuracy, and thin-wire machining. Fast auto-threading, consistent performance in extended runs, and high-quality surface finishes make it a strong fit for complex designs and small clearances.
| Specification | Value | Notes |
|---|---|---|
| Max Workpiece Size | 730 × 630 × 250 mm (28.74″ × 24.80″ × 9.84″) | Compact footprint with generous load space. |
| Max Workpiece Weight | 500 kg (≈1,100 lbs) | Stable cutting on medium-to-heavy parts. |
| Table Travel (X/Y/Z) | 400 × 300 × 255 mm (15.75″ × 11.81″ × 10.04″) | Precise positioning for complex features. |
| U/V Travel | ±60 mm | Supports advanced taper and offset work. |
| Max Taper | ±30° @ 80 mm (3.15″); option: ±45° @ 40 mm (1.57″) | Handles steep tapers on thicker stock. |
| Wire Diameter | 0.10–0.30 mm (≈0.004″–0.012″); option: 0.05 mm (≈0.002″) | Thin-wire option supports ultra-fine features. |
| Controller | FANUC 31i-WB | Modern control with iHMI interface. |
| Notable Features | AWF3 auto threading, iPulse3 discharge control, AI thermal compensation, Core Stitch | Improves uptime, finish quality, and accuracy on long runs. |
What’s different? Unlike older specs, the ROBOCUT supports thin-wire use down to ≈0.002″, offers taper options up to ±45° @ 1.57″ (with option), and runs faster, steadier unattended cycles with AWF3 and iPulse3. The work envelope and load ratings vary from older equipment, so we tailor machine choice to suit your part size and required tolerances.
Wire EDM Capabilities & Specs
With Wire EDM solutions available in Madison, WI, we handle parts ranging from micro-scale details to large workpieces, providing burr-free edges and reliable precision on conductive materials. See below for a general breakdown about wire EDMs:
Core Capabilities
| Capability | Spec | Why It Matters |
|---|---|---|
| Max Cutting Height | 16.5″ | Tackle tall parts and deep cavities without multiple setups. |
| Tolerance Maintained | ±0.0003″ | Hit critical features for aerospace, medical, and precision tooling. |
| Max Taper Angle | 45° | Produce complex profiles and reliefs in mold and die work. |
| Wire Diameter Range | .002″–.010″ | Cut ultra-fine details or heavier sections as the job requires. |
| Max Workpiece Weight | 1,800 lbs | Run large industrial components with stable fixturing. |
Work Envelope
| Axis | Travel | Notes |
|---|---|---|
| X / Y / Z | 21.7″ × 14.6″ × 12.2″ | Flexible capacity for varied part sizes and setups. |
Taper Capability by Thickness
| Workpiece Thickness | Typical Max Taper | Use Case |
|---|---|---|
| 12″ | ±10° | Thick tooling plates and heavy die sections. |
| 3.25″ | 30° | Mold components with angled relief features. |
| 1.93″ | 45° | Sharp internal corners and complex taper profiles. |
Looking for more info on a part or material? Contact us or give us a call at 573-646-3996 to discuss Wire EDM in Madison, WI.
Who Uses EDM Wire Cutting in Madison, WI?
Wire EDM goes beyond machine shops, serving as a precision method for those who need complex parts produced correctly on the first run. Our Wire EDM offering is perfect for:
- Project Managers & Directors: Ensure timelines hold by receiving parts that meet specifications and arrive when needed, cutting out delays.
- Prototype Engineers: Quickly validate and refine designs before moving into large-scale production.
- Quality Assurance Teams: Count on burr-free, uniform components that align with tough dimensional requirements.
- Compliance & Regulatory Specialists: Access inspection-ready components that adhere to required specifications.
- Maintenance & Reliability Engineers: Swap out damaged or worn parts with accurate replicas to reduce equipment downtime.
For work that demands accuracy, our Madison, WI, EDM wire cutting solutions deliver results on time and on budget.
Materials We Work With for Wire EDM
Electrically conductive materials are the only candidates for Wire EDM, but that includes many metals and alloys too hard for conventional tools. The process provides precise, burr-free finishes without distortion—whether you’re machining hardened steels, thin walls, or exotic alloys.
- Aluminum: Lightweight, corrosion-resistant, and widely machined for housings, brackets, prototypes, and high-performance parts.
- Stainless Steel: Resistant to corrosion and highly durable, ideal for medical, aerospace, and food-grade machining projects.
- Brass & Copper: Excellent machinability and conductivity make them go-to choices for electrical terminals, connectors, and fluid-related parts.
- Titanium: Corrosion-resistant and lightweight, frequently applied in aerospace designs, surgical tools, and precision performance parts.
- Tool Steels & Carbides: Able to handle hardened steels and tungsten carbide, standard for dies, molds, and long-lasting wear tools.
Wire EDM in Madison, WI, is part of the broader set of CNC machining processes we rely on to meet precise project requirements. Depending on the application, some projects use Wire EDM exclusively, while others combine it with turning, milling, or different machining strategies.
Why Roberson Machine Company for Madison, WI, Wire EDM Cutting?
For more than 20 years, Roberson Machine Company has delivered precision manufacturing solutions for industries where accuracy isn’t optional. With state-of-the-art CNC capabilities and dedicated wire EDM machinery, we provide expertise, dependable scheduling, responsive communication, and complete value-added services to Madison, WI, industries.
Other machining capabilities:
- Custom CNC Machining for Part Production
- CNC Machine Automation
- Oil and Gas Precision Machining
- Aerospace Manufacturing
- Automotive Part Manufacturing
- EDM Machining
- High Volume CNC Machining
- Industrial Automation
- Solar Panel Manufacturers
- Microscope Parts Precision Machining
Offering advanced machining services and expert guidance through the entire production process, the Roberson Machine Company is your go-to for surgical-grade wire EDM solutions. Discover details about our history and team, get a quote online, or call 573-646-3996 with questions regarding Madison, WI, Wire EDM services and machining capabilities.