Known for precision, Evansville, IN, Wire EDM cuts intricate shapes in hard or delicate materials without physical contact. Its capability keeps wire EDM at the core of Precision CNC Machining and today’s manufacturing.
Using advanced wire EDM (Electrical Discharge Machining) processes, Roberson Machine Company provides burr-free, reliable results for everything from prototypes to high-volume production runs. Give our team a call at 573-646-3996 or contact us online to learn more about how Evansville, IN, Wire EDM can accelerate and enhance your next project’s success.
Article Synopsis
- A summary of how wire EDM works, why the process doesn’t require physical contact, and where it delivers better results than conventional methods.
- Details on specifications and capabilities such as tolerances, taper angles, work size, and material types, showing if wire EDM is a match.
- Clear examples of real-world applications and industries like aerospace, medical, packaging, and energy, plus the roles responsible.
- What Roberson Machine Company brings to the table. This includes proven processes, modern equipment, and predictable lead times from prototype through production.
Whether for aerospace prototypes or medical-grade components, wire EDM enables design and production capabilities unmatched by other methods. We’ll detail in the next sections how wire EDM works, where it applies, and what to expect when you choose Roberson Machine Company.
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
See more about our machining capabilities, reviews, and information on Evansville, IN, Wire EDM from the blog and FAQs.
What Is Wire EDM Machining? | [city, IN, Precision CNC Services
Among our many CNC machining services, wire EDM provides specialized precision. Where traditional tools touch the part, wire EDM cuts conductive materials using a fine, electrically energized wire. Controlled sparks from the wire erode material along a programmed path, leaving highly accurate cuts without mechanical stress.
It excels where conventional machining falls short: intricate profiles, precise slots, sharp inside corners, and components made from hardened steels, titanium, carbide, and other demanding alloys. Parts come off the machine precise, burr-free, and ready to move straight into the next step of your build.
Real-World Applications for Evansville, IN, Wire EDM and Precision Cutting
Use wire EDM for jobs where standard machining can’t meet geometry, surface, or tolerance specs—like hard alloys, thin-walled parts, or components sensitive to cutting forces. Conductive metals like titanium, carbide, Inconel, and hardened steels are cut cleanly and burr-free with wire EDM.
Prototypes, fixtures, and production work in Evansville, IN, are often carried out with wire EDM. Common uses include:
- Aerospace: Fine turbine slots, seal features, and tooling inserts engineered to hold tolerance post heat treat.
- Military & Defense: Mission-critical assemblies and hardened alloys cut cleanly with sharp internal features.
- Automotive: Powertrain tooling, prototype parts, and mold inserts produced with precision internal clearances.
- Medical: Burr-free surgical instruments, implant components, and micro features in biocompatible metals.
- Packaging: Cleanly cut forming dies and wear pieces with smooth finishes that reduce downstream finishing.
- Food & Beverage: Washdown-ready stainless parts, corrosion-resistant and machined without added stress.
- Oil & Energy: High-pressure pump parts, sealing surfaces, and alloy components engineered for harsh service.
- Automation & Robotics: Motion-critical housings, fixtures, and components for automation systems with tight interior details.
- Firearm Manufacturing: Firearm slides, tooling, and internal pieces requiring accurate, burr-free machining.
- Consumer & Commercial Products: Branding dies, custom fixtures, and low- to mid-volume precision parts.
- OEM & Custom Applications: Whether it’s an R&D part or production in exotic alloys, if it’s conductive, wire EDM cuts it.
Have a project or a problem? Contact us online or call 573-646-3996 to discuss your Evansville, IN, wire EDM machining needs.
FANUC ROBOCUT α-C400iC: New Wire EDM Technology
We’ve added the FANUC ROBOCUT α-C400iC to increase precision, speed, and thin-wire cutting capability. The system offers quick auto-threading, reliable long runs, and fine surface finishes, making it ideal for complex geometries and tight 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? The ROBOCUT improves on legacy specs with thin-wire capability to about 0.002″, enhanced taper options (±45° @ 1.57″ with option), and more reliable unattended cutting using AWF3 and iPulse3. With different work envelope and load specs than previous units, we align the machine with your part size and tolerance goals.
Wire EDM Capabilities & Specs
In Evansville, IN, our Wire EDM work spans everything from micro components to heavy pieces, delivering sharp finishes and repeatable accuracy on conductive materials. Below is a general breakdown of 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 Evansville, IN.
Who Uses EDM Wire Cutting in Evansville, IN?
Wire EDM goes beyond machine shops, serving as a precision method for those who need complex parts produced correctly on the first run. We provide services ideal for:
- Project Managers & Directors: Maintain project flow with components that ship on time and match design requirements, reducing costly holdups.
- Prototype Engineers: Refine and prove out designs quickly to prepare for mass production.
- Quality Assurance Teams: Count on burr-free, uniform components that align with tough dimensional requirements.
- Compliance & Regulatory Specialists: Get inspection-ready parts built to exact specifications.
- Maintenance & Reliability Engineers: Maintain uptime with accurate, like-for-like replacements for worn or broken components.
If precision is non-negotiable, our Evansville, IN, EDM wire cutting service makes sure you stay on time and within 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: Light and corrosion-resistant, commonly used in machining housings, brackets, prototypes, and advanced performance parts.
- Stainless Steel: Resistant to corrosion and highly durable, ideal for medical, aerospace, and food-grade machining projects.
- Brass & Copper: Highly machinable and conductive, making them staples for electrical contacts, connectors, terminals, and fluid-handling parts.
- Titanium: Lightweight yet strong and corrosion-resistant—ideal for aerospace structures, surgical tools, and performance parts where strength-to-weight ratio matters.
- Tool Steels & Carbides: Known for toughness in cutting hardened steels and carbides, relied on for dies, molds, and precision wear components.
We meet exact specs with a mix of CNC machining processes, often centered on Wire EDM in Evansville, IN. 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 Evansville, IN, Wire EDM Cutting?
Roberson Machine Company has spent more than 20 years serving industries that require exacting levels of precision and accuracy. Our advanced CNC shop and dedicated wire EDM equipment let us pair technical expertise with reliable lead times, responsive support, and a wide array of value-added services for Evansville, IN, clients.
Additional machining capabilities we provide are:
- 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
- Military Manufacturing
- Medical Brace Manufacturing
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. Learn more about our team and history, contact us online for a quote, or call 573-646-3996 if you have any questions about Evansville, IN, Wire EDM services and our machining capabilities.