Known for precision, Milwaukee, WI, Wire EDM cuts intricate shapes in hard or delicate materials without physical contact. Because it achieves contact-free precision, wire EDM remains vital to Precision CNC Machining and manufacturing.
Roberson Machine Company applies advanced wire EDM (Electrical Discharge Machining) systems to achieve burr-free, consistent outcomes across projects from detailed prototypes to mission-critical production parts. Reach out at 573-646-3996 or contact us online to see how Milwaukee, WI, Wire EDM can improve speed and quality for your next project.
Article Synopsis
- A short explanation of how wire EDM works, how it cuts without contact, and where it outshines conventional machining.
- Review of specifications and capabilities—tolerances, tapers, envelopes, and materials—to confirm wire EDM fits your project’s needs.
- Simple examples of real-world applications and industries (aerospace, medical, packaging, energy) with notes on who oversees the work.
- Highlighting what Roberson Machine Company brings to the table, such as established processes, modern technology, and predictable timelines.
Wire EDM makes new design and manufacturing options possible—covering everything from aerospace prototypes to medical components—where other processes fall short. Below, we outline how the process functions, where it’s applied, and what working with Roberson Machine Company looks like.
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
Explore our machining capabilities along with customer reviews and success stories, plus insights into Milwaukee, WI, Wire EDM on the blog and FAQs.
What Is Wire EDM Machining? | [city, WI, Precision CNC Services
We include wire EDM as a specialized option within our wider CNC machining capabilities. Where traditional tools touch the part, wire EDM cuts conductive materials using a fine, electrically energized wire. The wire’s controlled sparks trace a programmed path, eroding material into accurate cuts with zero mechanical stress on the part.
This makes it ideal for features that are difficult—or impossible—to produce with conventional machining: intricate profiles, fine slots, sharp internal corners, and parts made from hardened steels, carbide, titanium, or other challenging alloys. Every part exits the process with accuracy, clean edges, and readiness for your next build stage.
Real-World Applications for Milwaukee, WI, 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. It handles conductive metals with burr-free precision, including titanium, carbide, Inconel, hardened steels, and more.
Prototypes, fixtures, and production work in Milwaukee, WI, are often carried out with wire EDM. Standard applications include:
- Aerospace: Fine turbine slots, seal features, and tooling inserts engineered to hold tolerance post heat treat.
- Military & Defense: Hardened alloys and mission assemblies where crisp internal corners and accuracy are vital.
- 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: Cleanly cut forming dies and wear pieces with smooth finishes that reduce downstream finishing.
- Food & Beverage: Durable stainless components for food-grade washdown, cut cleanly and stress-free.
- Oil & Energy: Sealing surfaces, pump parts, and alloy components built for high-pressure, corrosive conditions.
- Automation & Robotics: Fixtures, housings, and robotic components machined with fine internal accuracy.
- Firearm Manufacturing: Firearm slides, tooling, and internal pieces requiring accurate, burr-free machining.
- Consumer & Commercial Products: Precision branding dies, fixtures, and parts for consumer and commercial applications.
- 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 Milwaukee, WI, wire EDM machining needs.
FANUC ROBOCUT α-C400iC: New Wire EDM Technology
We’ve added a new FANUC ROBOCUT α-C400iC to expand cutting speed, precision, and thin-wire capability. 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? 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. 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
Our Milwaukee, WI, Wire EDM services handle everything from micro features to large, heavy workpieces, delivering clean edges 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. |
Questions about a part or material? Contact us or call 573-646-3996 for more information about Wire EDM in Milwaukee, WI.
Who Uses EDM Wire Cutting in Milwaukee, WI?
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. We deliver Wire EDM solutions for:
- Project Managers & Directors: Stay on schedule by getting parts delivered on time and built to spec, preventing expensive setbacks.
- Prototype Engineers: Quickly validate and refine designs before moving into large-scale 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: Obtain precision-matched replacements for failed parts, keeping downtime to a minimum.
If accuracy drives your success, our Milwaukee, WI, 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: Strong, corrosion-resistant, and relied on for medical equipment, aerospace hardware, and food-safe parts.
- Brass & Copper: Used extensively in electrical and fluid applications thanks to their conductivity and ease of machining.
- Titanium: Strong, light, and corrosion-resistant, used in aerospace, surgical instruments, and performance-driven parts.
- Tool Steels & Carbides: Ideal for shaping hardened steels and carbides, commonly used in molds, dies, and other high-wear parts.
We meet exact specs with a mix of CNC machining processes, often centered on Wire EDM in Milwaukee, WI. Certain projects depend on Wire EDM alone, while others benefit from pairing it with milling, turning, or other precision machining techniques.
Why Roberson Machine Company for Milwaukee, WI, Wire EDM Cutting?
Backed by 20 years in business, Roberson Machine Company continues to serve industries that cannot compromise on precision. 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 Milwaukee, WI, clients.
Additional machining capabilities we provide are:
- 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
The Roberson Machine Company provides advanced machining services and process expertise, making us a go-to for surgical-grade wire EDM. For more information on Milwaukee, WI, Wire EDM services, explore our team and history, request a quote online, or call 573-646-3996.