Respected in advanced manufacturing, Chicago, IL, Wire EDM offers unmatched precision for complex geometries and delicate materials. It can cut complex shapes in hard or delicate materials without physical contact, making wire EDM essential to Precision CNC Machining and production.
At Roberson Machine Company, we use advanced wire EDM (Electrical Discharge Machining) technology to deliver burr-free, repeatable results for everything from intricate prototypes to production-critical components. Give our team a call at 573-646-3996 or contact us online to learn more about how Chicago, IL, Wire EDM can accelerate and enhance your next project’s success.
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.
- Straightforward examples of real-world applications and industries (aerospace, medical, packaging, energy) and who inside those teams typically owns the work.
- An overview of what Roberson Machine Company brings to the table, including modern equipment, established processes, and consistent lead times.
Whether for aerospace prototypes or medical-grade components, wire EDM enables design and production capabilities unmatched by other methods. In the sections below, we’ll break down how it works, where it’s used, and what to expect when you work with 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
Discover our machining capabilities, success stories, and additional Chicago, IL, Wire EDM resources available on the blog and FAQs.
What Is Wire EDM Machining? | [city, IL, Precision CNC Services
Wire EDM is one of the specialized services included in our broader CNC machining capabilities. Unlike standard machining tools that make contact, wire EDM uses a fine, electrically charged wire to cut conductive metals. The process forms controlled sparks along the wire path, eroding material into highly accurate cuts without stressing the part.
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 Chicago, IL, Wire EDM and Precision Cutting
Wire EDM is the process of choice when conventional tools fall short on geometry, finish, or tolerance—particularly with difficult materials, thin walls, or parts unsuited for rigid cutting. This process machines conductive materials cleanly, producing burr-free parts in titanium, carbide, Inconel, hardened steels, and beyond.
Prototypes, fixtures, and production work in Chicago, IL, are often carried out with wire EDM. Common applications include:
- Aerospace: Complex turbine slots, sealing features, and precision tooling inserts that stay accurate through heat treat.
- Military & Defense: Hardened alloys and mission assemblies where crisp internal corners and accuracy are vital.
- Automotive: Mold inserts, powertrain tooling, and prototypes machined with tight internal clearances.
- Medical: Surgical tools, implant parts, and micro features machined burr-free in biocompatible alloys.
- Packaging: Cleanly cut forming dies and wear pieces with smooth finishes that reduce downstream finishing.
- Food & Beverage: Food-grade stainless components built for washdown service, free from stress or burrs.
- Oil & Energy: Pump components, sealing details, and alloy parts machined for corrosive, high-pressure use.
- Automation & Robotics: Motion-critical housings, fixtures, and components for automation systems with tight interior details.
- Firearm Manufacturing: Consistently accurate firearm slides, internals, and tooling with sharp, burr-free edges.
- Consumer & Commercial Products: Fixtures, branding dies, and precision parts produced for consumer and commercial needs.
- OEM & Custom Applications: Prototype one-offs through full production runs in hardened or exotic alloys—if conductive, we cut it.
Working on a project or facing a challenge? Contact us online or reach us at 573-646-3996 to go over your Chicago, IL, wire EDM machining needs.
FANUC ROBOCUT α-C400iC: New Wire EDM Technology
Our shop now includes a FANUC ROBOCUT α-C400iC, boosting cutting speed, precision, and thin-wire performance. It achieves efficient auto-threading, long stable runs, and clean surface finishes—suited for complex shapes and tight interior 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? Where legacy specs fall short, the ROBOCUT delivers ≈0.002″ thin-wire cutting, advanced taper choices (±45° @ 1.57″ with option), and stable, faster unattended operation powered by AWF3 and iPulse3. Its work envelope and load limits differ from past models, so we fit the right unit to your part’s size and tolerance needs.
Wire EDM Capabilities & Specs
With Wire EDM solutions available in Chicago, IL, we handle parts ranging from micro-scale details to large workpieces, providing burr-free edges and reliable precision on conductive materials. Here’s 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. |
Got questions about parts or materials? Contact us or call 573-646-3996 today for information on Wire EDM in Chicago, IL.
Who Uses EDM Wire Cutting in Chicago, IL?
Wire EDM isn’t just for machine shops—it’s a precision solution for anyone responsible for getting complex parts made right the first time. These services are the right match for:
- Project Managers & Directors: Stay on schedule by getting parts delivered on time and built to spec, preventing expensive setbacks.
- Prototype Engineers: Validate and tweak designs early, reducing risk before entering large-scale production.
- Quality Assurance Teams: Get parts that are burr-free and dimensionally accurate, meeting even the strictest tolerance standards.
- Compliance & Regulatory Specialists: Access inspection-ready components that adhere to required specifications.
- Maintenance & Reliability Engineers: Get exact replacement components to restore operations quickly and avoid extended outages.
If your job depends on precision, our Chicago, IL, EDM wire cutting capabilities help you get there on time and within budget.
Materials We Work With for Wire EDM
Only electrically conductive materials can be cut with Wire EDM, but that makes it perfect for metals and alloys where traditional machining falls short. The method produces accurate, burr-free parts without stress or heat distortion—from thin-walled pieces and hardened steels to advanced exotic alloys.
- Aluminum: Corrosion-resistant and lightweight, frequently machined into housings, brackets, prototypes, and precision parts.
- Stainless Steel: Resistant to corrosion and highly durable, ideal for medical, aerospace, and food-grade machining projects.
- Brass & Copper: Valued for conductivity and machinability, common in contacts, connectors, and fluid-handling systems.
- Titanium: Corrosion-resistant and lightweight, frequently applied in aerospace designs, surgical tools, and precision performance parts.
- Tool Steels & Carbides: Engineered for cutting hardened steels and carbide, making them critical in dies, molds, and wear components.
Wire EDM in Chicago, IL, is one of many CNC machining processes we use to meet your specs. 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 Chicago, IL, Wire EDM Cutting?
For over two decades, Roberson Machine Company has provided precision machining services to industries that demand absolute accuracy. By leveraging a modern CNC shop and specialized wire EDM systems, we deliver technical skill, consistent lead times, and a full suite of value-added services to Chicago, IL, customers.
Our shop offers a range of 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
Backed by advanced machining and expert support from start to finish, the Roberson Machine Company delivers surgical-grade wire EDM solutions. Discover details about our history and team, get a quote online, or call 573-646-3996 with questions regarding Chicago, IL, Wire EDM services and machining capabilities.