Description

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Precision Wire EDM Plates are manufactured using CNC traveling-wire electrical discharge machines to achieve complex contours, narrow slots, and sharp internal radii that standard milling cannot accomplish.

What it is: Custom flat metal plates and profiles featuring complex internal/external profiles and vertical wall geometries.

Suitable Parts: Stripper plates, die inserts, punch holders, stripper brackets, mold sub-plates, and precision positioning shims.

Core Machining Capability: 4-axis wire cutting with automated wire threading, capable of taper cuts up to +/- 30 degrees, maintaining sub-micron feed stability, and processing hardened tool steels directly without post-heat-treat distortion.

Manufacturing Insight: Operating high-precision submerged wire EDM systems (Sodick and Mitsubishi) allows our facility to maintain strict edge squareness and eliminate recast layers on critical mating components before final assembly.

Technical Specifications

Parameter	Specification Range
Material	Tool Steel (D2, SKD11, A2, O1), Stainless Steel (304, 316, 420, 17-4PH), Carbide, Titanium, Brass, Aluminum
Size Capability	Max working envelope: 600 mm x 400 mm x 300 mm (Custom sizes evaluated per drawing)
Dimensional Tolerance	Down to +/- 0.001 mm (+/- 0.00004 in)
Positioning Accuracy	+/- 0.002 mm per full travel
Surface Roughness	Ra 0.1 um to 0.8 um (Multi-cut operation capability)
Processing Range	Plate thickness up to 300 mm; Wire diameter range 0.05 mm to 0.30 mm
Equipment/Process	CNC Submerged Wire EDM, CNC Surface Grinding, CMM Verification

Key Features

Dimensional Accuracy: Maintains straightness, parallelism, and squareness within strict geometric dimensioning and tolerancing (GD&T) limits.

Tight Tolerances: Capable of holding micro-tolerances down to +/- 0.001 mm for mating die components and alignment plates.

Complex Geometry: Executes intricate internal profiles, narrow clearance slots, and sharp inside corners with minimal radii (R >= 0.03 mm using 0.05 mm wire).

Repeatability: Closed-loop linear glass scale feedback ensures consistent dimensions across multi-piece production runs.

Surface Quality: Multi-pass cutting strategy minimizes the EDM recast layer and surface micro-fissures, reducing secondary polishing time.

Small Batch Production: Efficient setup without hard tooling makes low-volume runs and rapid prototyping economically viable.

Applications

Automotive: Progressive stamping die inserts, blanking dies, and transfer press tooling plates.

Medical: Surgical device assembly fixtures, diagnostic instrument housings, and implant manufacturing tooling.

Aerospace: Turbine test rig components, structural shims, and high-temperature alloy positioning plates.

Automation: Custom robotic end-effector plates, precision alignment brackets, and modular fixture sub-bases.

Electronics: Connector mold inserts, terminal stamping dies, and semiconductor test socket plates.

Industrial Equipment: Hydraulic valve plates, gear shaper guides, and wear-resistant machinery components.

Materials & Surface Finishes

Material Options
Tool Steels: D2, SKD11, A2, O1, M2 (supplied in annealed or pre-hardened conditions up to 60 HRC).

Stainless Steels: SUS 304, SUS 316, SUS 420, 17-4PH.

Non-Ferrous & Special Alloys: Aluminum (6061, 7075), Brass, Copper, Titanium (Gr. 5), Tungsten Carbide.

Surface Finishes
As-Cut EDM Finish: Standard multi-pass texture (Ra 0.4 - 0.8 um).

Fine Finish: Mirror-like wire finish via 4-pass or 5-pass cutting (Ra 0.1 - 0.2 um).

Post-Processing: Surface grinding, Blanchard grinding, deburring, bead blasting, heat treatment (Vacuum hardening, cryogenic treatment), and plating/coatings (TiN, TiAlN outsourced to certified partners).

Customization & OEM

Drawing / CAD Files: Accepts 2D drawings (PDF, DXF, DWG with GD&T) and 3D models (STEP, IGES, Parasolid, SolidWorks).

Custom Dimensions: Plates cut to exact perimeter profiles and thickness specifications per customer print.

Tolerance Requirements: Custom tolerance allocations managed per engineering notes, including fit-up matching for assembled plates.

Material Selection: Sourcing from certified mills with full Material Test Reports (MTRs) provided upon request.

Prototype & Mass Production: Flexible manufacturing cell supports single-piece rapid prototyping through to production runs of 500+ matching plates.

Quality Control

Manufacturing processes are monitored through documented inspection protocols utilizing calibrated measuring instruments under our ISO 9001-aligned quality management system:

Dimensional Inspection: 2.5D Optical Comparator and CNC Coordinate Measuring Machine (CMM) verification for complex profiles and hole patterns.

Surface Roughness Testing: Portable surface profilometer verifying Ra values against drawing specifications.

Material Inspection: Incoming raw material verification for hardness, chemical composition, and ultrasonic testing certificates.

Final Inspection: 100% dimensional check on critical dimensions and visual inspection for burrs, edge cleanliness, and packaging security before shipment.

Packaging & Delivery

Protective Packaging: Individual vacuum-sealing with VCI (Volatile Corrosion Inhibitor) anti-rust paper and foam cushioning to prevent transit damage.

Batch Identification: Laser-etched part numbers, revision levels, and heat codes matching inspection reports.

Export Packaging: ISPM 15 compliant fumigated wooden crates or heavy-duty double-wall corrugated cartons for international freight.

Lead Time: Standard prototype delivery in 5 to 10 business days; production schedules confirmed upon order review.

FAQ

Q: What is your Minimum Order Quantity (MOQ)?

A: No strict MOQ. We process single-piece prototypes as well as regular production batches.

Q: What is the tightest tolerance you can achieve?

A: We routinely hold dimensional tolerances down to +/- 0.001 mm and positional tolerances within 0.002 mm, depending on material thickness and geometry.

Q: Can you supply material test reports (MTRs)?

A: Yes. Full material traceability certificates and dimensional inspection reports are supplied with every order upon request.

Q: What file formats do you require for quoting?

A: Please provide a 2D PDF drawing containing critical dimensions, tolerances, and surface finish callouts, accompanied by a 3D STEP or IGES file.

Q: How do you handle hard materials?

A: Wire EDM cuts conductive materials regardless of hardness. We frequently machine pre-hardened tool steels up to 60 HRC and tungsten carbide without post-machining distortion.

Q: What is the standard lead time?

A: Prototypes typically ship in 5 to 10 days. Batch production timelines are established based on part complexity and quantity during quote review.