Respected in advanced manufacturing, Indianapolis, IN, Wire EDM offers unmatched precision for complex geometries and delicate materials. That’s why wire EDM is central to Precision CNC Machining and advanced manufacturing.
At Roberson Machine Company, our wire EDM (Electrical Discharge Machining) technology delivers accurate, burr-free results, from complex prototypes through production-critical assemblies. To discuss how Indianapolis, IN, Wire EDM can drive success for your next project, call our team at 573-646-3996 or contact us online.
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.
- Straightforward examples of real-world applications and industries (aerospace, medical, packaging, energy) and who inside those teams typically owns the work.
- What Roberson Machine Company brings to the table. This includes proven processes, modern equipment, and predictable lead times from prototype through production.
From aerospace parts to medical components, wire EDM provides design and production options beyond the reach of conventional processes. 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
Check out our machining capabilities, success stories, and extra content about Indianapolis, IN, Wire EDM on the blog and FAQs.
What Is Wire EDM Machining? | [city, IN, Precision CNC Services
Within our full range of CNC machining services, wire EDM stands out as a specialized process. Instead of using a cutting tool that physically contacts the workpiece, wire EDM shapes conductive metals with a thin, electrically charged wire. 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. Parts come off the machine precise, burr-free, and ready to move straight into the next step of your build.
Real-World Applications for Indianapolis, IN, 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 delivers burr-free, precise cuts on conductive metals such as titanium, carbide, Inconel, and hardened steels.
Teams use wire EDM in Indianapolis, IN, for prototypes, fixtures, and full production runs. Examples of applications include:
- Aerospace: Precision turbine slots, seal details, and tooling inserts that maintain tolerances after heat treating.
- Military & Defense: Critical defense assemblies and hardened alloys machined burr-free with tight internal edges.
- 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: Wear parts and forming dies with crisp edges and fine finishes to minimize rework.
- Food & Beverage: Stainless steel components machined burr-free and corrosion-resistant for sanitary washdown use.
- Oil & Energy: Sealing surfaces, pump parts, and alloy components built for high-pressure, corrosive conditions.
- Automation & Robotics: Robotics fixtures, housings, and motion components requiring precise internal geometry.
- Firearm Manufacturing: Slides, tooling, and inner firearm parts manufactured with clean edges and repeatable tolerances.
- Consumer & Commercial Products: Branding dies, custom fixtures, and low- to mid-volume precision parts.
- OEM & Custom Applications: Single R&D parts to large production jobs in conductive alloys, even exotic or hardened.
Got a project or issue? Contact us online or call 573-646-3996 to talk about your Indianapolis, IN, wire EDM machining requirements.
FANUC ROBOCUT α-C400iC: New Wire EDM Technology
We’ve brought in a FANUC ROBOCUT α-C400iC to raise throughput, precision, and thin-wire capabilities. With quick auto-threading, steady long-duration operation, and excellent surface finish, it excels at producing intricate features and precise internal gaps.
| 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. 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
In Indianapolis, IN, our Wire EDM work spans everything from micro components to heavy pieces, delivering sharp finishes and repeatable accuracy 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 Indianapolis, IN.
Who Uses EDM Wire Cutting in Indianapolis, IN?
Wire EDM does more than serve machine shops—it’s the precision process for anyone who can’t afford mistakes when making complex parts. 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: Test and adjust designs rapidly before scaling into full production.
- Quality Assurance Teams: Receive dimensionally consistent, burr-free components that meet demanding tolerance requirements.
- Compliance & Regulatory Specialists: Receive parts manufactured to precise specs and prepared for inspection.
- Maintenance & Reliability Engineers: Swap out damaged or worn parts with accurate replicas to reduce equipment downtime.
When projects hinge on precision, our Indianapolis, IN, EDM wire cutting expertise ensures deadlines and budgets are met.
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: Lightweight, corrosion-resistant, and widely machined for housings, brackets, prototypes, and high-performance parts.
- Stainless Steel: Strong, corrosion-resistant, and relied on for medical equipment, aerospace hardware, and food-safe parts.
- Brass & Copper: Valued for conductivity and machinability, common in contacts, connectors, and fluid-handling systems.
- 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: Tough enough to cut hardened steels and tungsten carbide, essential for dies, molds, punches, and other wear parts.
Among the range of CNC machining processes we offer, Wire EDM in Indianapolis, IN, stands out as a key method for meeting exact specifications. 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 Indianapolis, IN, 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 Indianapolis, IN, industries.
Our full set of machining capabilities also covers:
- 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
- Military Manufacturing
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 Indianapolis, IN, Wire EDM services and machining capabilities.