In modern manufacturing, Green Bay, WI, Wire EDM is a leading process for accuracy and complexity. Its capability keeps wire EDM at the core of Precision CNC Machining and today’s manufacturing.
At Roberson Machine Company, our wire EDM (Electrical Discharge Machining) technology delivers accurate, burr-free results, from complex prototypes through production-critical assemblies. Interested in learning how Green Bay, WI, Wire EDM can support your next project? Call 573-646-3996 or contact us online.
Article Synopsis
- A quick look at how wire EDM works, why it cuts without contact, and when it outperforms conventional machining.
- Outline of specifications and capabilities—tolerances, tapers, materials, envelopes—so you can evaluate if wire EDM meets your requirements.
- Clear examples of real-world applications and industries like aerospace, medical, packaging, and energy, plus the roles responsible.
- 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 following sections cover how wire EDM operates, its uses, and what you can expect partnering 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
Learn more about our machining capabilities, success stories and reviews, and other information about Green Bay, 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. Rather than relying on direct-contact tooling, wire EDM forms conductive metals with a thin wire carrying electrical charge. Controlled sparks from the wire erode material along a programmed path, leaving highly accurate cuts without mechanical stress.
That’s why it’s the go-to method for features conventional machining can’t achieve: intricate profiles, narrow slots, sharp internal corners, and components built from hardened steels, titanium, carbide, or other tough alloys. The process produces clean, accurate cuts that are ready for assembly, finishing, or the next stage of production.
Real-World Applications for Green Bay, 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 delivers burr-free, precise cuts on conductive metals such as titanium, carbide, Inconel, and hardened steels.
Prototypes, fixtures, and production work in Green Bay, WI, are often carried out with wire EDM. Examples of applications include:
- Aerospace: Complex turbine slots, sealing features, and precision tooling inserts that stay accurate through heat treat.
- Military & Defense: Mission-critical assemblies and hardened alloys cut cleanly with sharp internal features.
- Automotive: Automotive powertrain tooling, inserts, and prototype parts requiring fine interior tolerances.
- Medical: Biocompatible metal implants, surgical devices, and micro features produced clean and burr-free.
- Packaging: Forming dies and wear parts with sharp edges and smooth finishes to reduce post-processing.
- Food & Beverage: Food-grade stainless components built for washdown service, free from stress or burrs.
- Oil & Energy: Sealing surfaces, pump parts, and alloy components built for high-pressure, corrosive conditions.
- Automation & Robotics: Precision fixtures, housings, and motion assemblies designed with close internal clearances.
- Firearm Manufacturing: Slides, internal components, and tooling where repeatable accuracy and clean edges matter.
- Consumer & Commercial Products: Low- to mid-volume precision components, branding dies, and custom fixtures.
- OEM & Custom Applications: Prototype one-offs through full production runs in hardened or exotic alloys—if conductive, we cut it.
Whether it’s a project or a machining challenge, contact us online or call 573-646-3996 to discuss your Green Bay, WI, wire EDM machining requirements.
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 provides rapid auto-threading, dependable stability over long runs, and smooth surface finishes—perfect for intricate features and narrow internal spaces.
| 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
Our Green Bay, WI, Wire EDM services handle everything from micro features to large, heavy workpieces, delivering clean edges and repeatable accuracy on conductive materials. You’ll find a general breakdown of wire EDMs below:
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. |
Need details on a part or material? Contact us or call 573-646-3996 to learn more about Wire EDM in Green Bay, WI.
Who Uses EDM Wire Cutting in Green Bay, WI?
More than a tool for machine shops, Wire EDM is a precision option for professionals who demand complex parts be right from the start. Our Wire EDM capabilities are suited for:
- Project Managers & Directors: Keep production moving with parts delivered on spec and on schedule, minimizing budget-wasting delays.
- Prototype Engineers: Validate and tweak designs early, reducing risk before entering large-scale production.
- Quality Assurance Teams: Obtain components free of burrs and built to the tightest dimensional requirements.
- Compliance & Regulatory Specialists: Obtain parts that meet strict specifications and pass inspection with confidence.
- Maintenance & Reliability Engineers: Maintain uptime with accurate, like-for-like replacements for worn or broken components.
If precision is non-negotiable, our Green Bay, WI, EDM wire cutting service makes sure you stay 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: Widely used in aerospace, medical, and food industries thanks to its strength and corrosion resistance.
- Brass & Copper: Known for machinability and conductivity, often used for electrical contacts, connectors, and fluid-handling equipment.
- Titanium: Light but exceptionally strong, titanium is chosen for aerospace, surgical, and performance applications.
- Tool Steels & Carbides: Tough enough to cut hardened steels and tungsten carbide, essential for dies, molds, punches, and other wear parts.
We meet exact specs with a mix of CNC machining processes, often centered on Wire EDM in Green Bay, WI. Some parts are best produced solely with Wire EDM, while others require it alongside milling, turning, or complementary precision processes.
Why Roberson Machine Company for Green Bay, WI, Wire EDM Cutting?
For over two decades, Roberson Machine Company has provided precision machining services to industries that demand absolute accuracy. From our modern CNC shop to our dedicated wire EDM equipment, we combine technical expertise with dependable lead times, responsive service, and a full range of value-added services to Green Bay, WI, customers.
Our shop offers a range of 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. For more information on Green Bay, WI, Wire EDM services, explore our team and history, request a quote online, or call 573-646-3996.