Electrical Discharge Machining (EDM) is used because it offers several advantages over traditional machining methods, particularly when dealing with complex shapes, hard materials, or delicate parts. EDM utilizes electrical sparks to remove material, allowing for high precision, intricate cuts, and the machining of parts that are otherwise difficult or impossible to produce using conventional tools.

What Materials Can Be Processed Using Wire EDM Machining? A good rule of thumb. If it can conduct electricity. You can burn it. Some examples of what can be burned. Copper, Carbide Tungsten, Bronze, Carbon steel, Inconel, Stainless steel, Hastelloy, Kovar, Titanium, Carbon graphite, High alloy steel.

Here's a more detailed breakdown of why EDM is used:

1. Machining of Complex Shapes: EDM can produce intricate shapes, including internal contours and sharp internal corners, that are difficult or impossible to achieve with traditional cutting tools. It's particularly useful for creating complex cavities in molds, dies, and other tooling.

2. Hard Materials: EDM can machine extremely hard materials, such as tool steel, tungsten carbide, and titanium, which are challenging to cut with conventional methods. The hardness of the material doesn't significantly affect the EDM process, allowing for consistent precision.

3. Delicate and Thin Parts: Because EDM involves no direct contact between the tool and the workpiece, it can be used to machine delicate and thin parts without causing damage or distortion. This is especially beneficial for parts that might be easily deformed or broken during traditional machining.

4. High Precision: EDM can achieve very tight tolerances and high levels of accuracy. This makes it suitable for applications requiring precise dimensions and intricate features, such as in the aerospace and medical industries.

5. Good Surface Finish: EDM can produce a good surface finish, which can be further improved by redundant finishing passes. This can be advantageous for applications requiring a smooth or polished surface.

6. Versatility: EDM is versatile and can be used for a wide range of applications, including making molds, dies, prototypes, and production parts. It can be used in various industries, such as aerospace, automotive, electronics, and moldmaking.

7. Cost-Effectiveness: In some cases, EDM can be more cost-effective than traditional machining methods, especially when dealing with complex geometries or hard materials. For example, EDM can eliminate the need for multiple machining steps or secondary finishing operations, saving time and money.


In summary, EDM is a powerful tool for achieving complex shapes, machining hard materials, and producing high-precision parts with a good surface finish. Its versatility and cost-effectiveness make it a valuable option for a wide range of manufacturing applications.