Precision Electrical Discharge Machining | Core Solutions for Complex Cavities and Special Material Molding

Humanoid Robots | aerospace | medical devices | NEV

Product Brief

As a manufacturer with core technologies in precision EDM and complex electrode manufacturing, we provide professional precision EDM services , specializing in the precision manufacturing of complex three-dimensional cavities, deep and narrow grooves, micro-holes, and high-precision surfaces for various conductive materials.

We possess a complete technical system, from precision EDM machine tools and multi-axis CNC systems to intelligent electrode libraries, covering high-end manufacturing fields such as precision injection molds, die-casting molds, stamping dies, turbine disk tenons for aero-engines, precision parts for medical devices, and high-hardness material forming. We deeply understand the extreme requirements for cavity accuracy, surface roughness, edge sharpness, and processing efficiency under challenges such as high geometric complexity, difficult material processing, stringent surface quality requirements, and processing stability. We are committed to achieving superior shape replication accuracy, excellent surface integrity, and stable process repeatability through the integration of intelligent discharge control, multi-axis linkage strategies, and precision electrode engineering.

Core Advantages

(1) Precision machining of complex three-dimensional cavities and deep and narrow structures

① The multi-axis linkage corner clearing and side machining technology
adopts a four-axis/five-axis EDM machine tool, combined with a precision indexing fixture, to realize deep cavity bottom corner clearing, side slope machining and continuous EDM forming of complex surfaces. The side wall verticality can reach 89.5°, and the minimum inner radius R≤0.05mm, avoiding interference and tool marks in traditional machining.

② High aspect ratio narrow groove and micro structure forming
can process narrow groove structures with a width of 0.1-2.0mm and an aspect ratio of ≥15:1, as well as fine features such as micro gears and micro channels. The dimensional accuracy is ±0.005mm and the straightness of the side wall is ≤0.01mm/100mm. It is suitable for precision mold inserts and micro system parts.

③ Machining of blind holes and irregular holes with ultra-large depth-to
-diameter ratio: For deep hole structures such as cooling water holes and exhaust holes, electrical discharge forming is performed using tube electrodes or special electrodes. This can achieve the machining of deep blind holes with diameters of Φ0.3-Φ3mm and depth-to-diameter ratios of ≥50:1. The shape of the hole bottom is controllable and the hole wall has no taper.

(2) Stress-free machining of high-hardness materials and special alloys

① High-precision cavity machining of cemented carbide and hardened steel:
Direct electrical discharge molding of complex cavities for mold steel and cemented carbide (such as YG15) with hardness ≥ HRC 60. There is no mechanical cutting force during the machining process, avoiding material breakage and stress deformation. The cavity dimensional accuracy can reach ±0.005mm.

② High-efficiency electrical discharge machining of high-temperature alloys and titanium alloys
: For difficult-to-machine materials such as Inconel 718 and Ti6Al4V, special graphite electrodes and optimized discharge parameters are used to achieve a material removal rate of 0.5-3 mm³/min, with no microcracks on the machined surface and the heat-affected layer depth controllable to ≤0.02 mm.

③ Polycrystalline diamond (PCD) and cubic boron nitride (CBN) forming
is used to precisely shape and trim the cutting edge of superhard tool materials, which can achieve precise control of the cutting edge radius R0.01-0.1mm, with no chipping on the cutting edge, and greatly improve the life and consistency of superhard tools.

(3) Intelligent discharge control and surface quality optimization

① Adaptive pulse power supply and intelligent gap control:
Equipped with a CNC precision pulse power supply, the discharge time, interval and current are adjusted in real time according to the discharge state. Combined with the intelligent gap servo system, stable discharge is achieved, the processing efficiency is improved by 20% and the electrode loss ratio is reduced to ≤0.3%.

② Precise control of surface roughness through multi-level process:
By combining coarse, medium and fine discharge parameters, the surface roughness Ra can be precisely controlled from 0.05 to 3.2 μm. Mirror EDM can achieve Ra≤0.1 μm, and matte or textured surfaces can be obtained as needed.

③ Online electrode loss compensation and morphology monitoring:
A 3D probe is used to measure electrode loss online and automatically compensate for the machining path to ensure the accuracy of cavity dimensions. Combined with a machining area monitoring system, the discharge status is observed in real time to prevent abnormal discharge.

(4) Precision electrode engineering and rapid response capability

① Complex electrode multi-axis precision machining and inspection:
Equipped with a five-axis high-speed milling center, it can process electrode materials such as graphite, copper-tungsten, and copper. The minimum electrode feature size is ≥0.1mm, the electrode accuracy is ±0.002mm, and online measurement and correction of the electrode can be realized.

② Multi-electrode combination and automated changeover technology
adopts a multi-electrode multi-processing strategy for complex cavities. The automatic electrode exchange system (AEC) enables the automatic identification and changeover of up to 30 electrodes, reducing manual intervention and improving processing consistency.

③ The discharge process database and rapid process development
establish a process parameter database covering commonly used material combinations (steel-copper, steel-graphite, cemented carbide-copper-tungsten, etc.) to support rapid process development of new parts, with a first-piece success rate of ≥90%.

Technical Parameter

Part type	Main features and typical applications	Machinable materials	Core processing advantages
Precision injection mold cavity	Complex free-form surfaces, fine ribs, and deep cavity structures; high surface quality requirements (mirror finish or textured finish).	Die steel (S136, NAK80, 718), cemented carbide	High surface quality, replication of complex geometries, and ability to fabricate slender electrodes.
Die casting mold and forging mold cavity	Large, deep cavities; materials prone to deformation under heat; requiring high wear resistance and resistance to thermal fatigue.	Hot work die steel (H13, 8407), high thermal conductivity copper alloy	Stress-free machining, preserving material properties: segmented machining technology for large electrodes.
aircraft engine turbine disk tenon	Three-dimensional curved tenon and groove, made of a difficult-to-machine high-temperature alloy; requiring high precision and consistency.	Nickel-based superalloys (Inconel 718, Waspaloy), titanium alloys	Multi-axis linkage machining of complex surfaces, no recast layer control, and high batch production consistency.
Precision parts for medical devices	Microstructured, high-hardness biocompatible materials; requiring no burrs and no contamination.	Stainless steel (316L), titanium alloy (CP-Ti, Ti6Al4V), cobalt-chromium alloy	Micro-feature processing capabilities, clean production environment, integrated surface passivation
High-precision stamping dies and progressive dies	For materials with minute gaps (≤0.01mm) and high hardness; requiring sharp cutting edges and long service life.	Powder high-speed steel (ASP series), cemented carbide, alloy tool steel	Precision control with minute gaps ensures no chipping on the cutting edge and eliminates the need for post-machining grinding.

customization capabilities

OEM and ODM manufacturing support;
Machining based on customer drawings, 3D models, or physical samples;
Prototype development, small-batch trial production, and volume manufacturing;
Processing of difficult-to-machine materials such as cemented carbide, tool steel, titanium alloys, and high-temperature alloys;
Precision forming of deep grooves, narrow slots, sharp internal corners, irregular curved surfaces, and complex cavities.

Packaging and Shipping

We design suitable packaging solutions according to the structure, size, surface requirements, and shipping method of precision sinker EDM components. The goal is to reduce the risk of impact, scratches, moisture, and corrosion during transportation.

Common packaging options include:

Individual or grouped protective packaging to prevent parts from rubbing against each other;
Extra protection for critical areas such as high-precision surfaces, formed surfaces, sharp corners, and narrow grooves;
Use of anti-rust oil, VCI paper, desiccants, or vacuum packaging when required;
Cartons, wooden cases, pallets, or reinforced packaging depending on part weight and shipping distance;
Export-ready packaging solutions suitable for international transportation.

Everything You Need to Know

Do you offer custom manufacturing for precision sinker EDM components?

Yes. We provide custom precision sinker EDM services based on customer drawings, samples, 3D models, or technical requirements. Our services cover prototype development, small-batch trial production, and volume manufacturing.

Can you manufacture parts according to our drawings or samples?

Yes. Customers can provide 2D drawings, 3D models, physical samples, or technical specifications. Our engineering team will evaluate manufacturability based on the material, structure, accuracy requirements, tolerances, and surface finish requirements.

What is the minimum order quantity?

The typical minimum order quantity is 10 pieces. The exact MOQ can be discussed flexibly depending on the part structure, material, machining difficulty, and project requirements.

Can you make samples before mass production?

Yes. We can provide samples or prototypes before mass production, allowing customers to verify dimensions, check assembly fit, conduct functional testing, and confirm the manufacturing process.

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