Known for precision, Colorado Springs, CO, 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.
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 Colorado Springs, CO, Wire EDM can accelerate and enhance your next project’s success.
Article Synopsis
- A concise breakdown of how wire EDM works, its contact-free cutting process, and the cases where it’s superior to traditional machining.
- Review of specifications and capabilities—tolerances, tapers, envelopes, and materials—to confirm wire EDM fits your project’s needs.
- 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.
Wire EDM makes new design and manufacturing options possible—covering everything from aerospace prototypes to medical components—where other processes fall short. The sections below explain how wire EDM works, its applications, and what to expect from 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
Find details on our machining services, reviews and success stories, and more about Colorado Springs, CO, Wire EDM in the blog and FAQs.
What Is Wire EDM Machining? | [city, CO, Precision CNC Services
Wire EDM is one of the specialized services included in our broader CNC machining capabilities. Wire EDM replaces direct cutting tools with a thin, charged wire to shape conductive metals. The process forms controlled sparks along the wire path, eroding material into highly accurate cuts without stressing the part.
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. The process produces clean, accurate cuts that are ready for assembly, finishing, or the next stage of production.
Real-World Applications for Colorado Springs, CO, Wire EDM and Precision Cutting
Wire EDM is ideal when conventional cutting can’t achieve the needed accuracy, finish, or tolerance, including on hard-to-machine metals, thin walls, or delicate parts. It handles conductive metals with burr-free precision, including titanium, carbide, Inconel, hardened steels, and more.
Wire EDM in Colorado Springs, CO, supports prototypes, tooling fixtures, and full-scale production jobs. Typical applications include:
- Aerospace: Complex turbine slots, sealing features, and precision tooling inserts that stay accurate through heat treat.
- Military & Defense: Hardened alloy parts and defense assemblies requiring distortion-free machining and precise corners.
- Automotive: Mold inserts, powertrain tooling, and prototypes machined with tight internal clearances.
- Medical: Burr-free machining for surgical tools, implant parts, and micro features in medical-grade alloys.
- Packaging: Precision forming dies and durable wear components cut with clean edges and smooth finishes.
- Food & Beverage: Stainless steel components machined burr-free and corrosion-resistant for sanitary washdown use.
- Oil & Energy: Alloy components, pump parts, and sealing features designed for service in high-pressure, corrosive systems.
- Automation & Robotics: Robotics fixtures, housings, and motion components requiring precise internal geometry.
- Firearm Manufacturing: Internal parts, slides, and firearm tooling cut to deliver repeatable precision and crisp edges.
- Consumer & Commercial Products: Fixtures, branding dies, and precision parts produced for consumer and commercial needs.
- OEM & Custom Applications: From R&D one-offs to production runs in exotic or hardened materials—if it’s conductive, we can cut it.
Need help with a project or part? Contact us online or call 573-646-3996 to review your Colorado Springs, CO, 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. 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 capacity differ from older units, so we’ll match the machine to your part size and tolerance needs.
Wire EDM Capabilities & Specs
Across Colorado Springs, CO, our Wire EDM services are suited for jobs from intricate features to heavy-duty workpieces, producing accurate, burr-free results 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. |
Have a question about parts or materials? Contact us or reach us at 573-646-3996 for details on Wire EDM in Colorado Springs, CO.
Who Uses EDM Wire Cutting in Colorado Springs, CO?
More than a tool for machine shops, Wire EDM is a precision option for professionals who demand complex parts be right from the start. These services are the right match for:
- Project Managers & Directors: Maintain project flow with components that ship on time and match design requirements, reducing costly holdups.
- Prototype Engineers: Confirm and improve prototypes fast, then transition smoothly to production.
- Quality Assurance Teams: Receive dimensionally consistent, burr-free components that meet demanding tolerance 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.
If accuracy drives your success, our Colorado Springs, CO, EDM wire cutting capabilities provide timely, cost-effective results.
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: Tough and resistant to corrosion, making it essential for medical devices, aerospace applications, and food-grade parts.
- Brass & Copper: Known for machinability and conductivity, often used for electrical contacts, connectors, and fluid-handling equipment.
- 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.
Among the range of CNC machining processes we offer, Wire EDM in Colorado Springs, CO, stands out as a key method for meeting exact specifications. In some cases Wire EDM is the sole solution, in others it’s integrated with milling, turning, or related processes for optimal results.
Why Roberson Machine Company for Colorado Springs, CO, Wire EDM Cutting?
For decades, Roberson Machine Company has specialized in delivering precision manufacturing solutions where accuracy is critical. Combining our modern CNC shop with wire EDM equipment, we offer technical precision, on-time delivery, responsive service, and comprehensive value-added services for Colorado Springs, CO, companies.
Other machining capabilities:
- CNC Lathe Machining
- 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
Backed by advanced machining and expert support from start to finish, the Roberson Machine Company delivers surgical-grade wire EDM solutions. Check out our team and company background, connect with us online, or call 573-646-3996 for answers about Colorado Springs, CO, Wire EDM services.