Wire EDM Contract Manufacturing: Precision Components from Conductive Materials.
Condor® Custom Solutions provides wire EDM contract manufacturing for workpieces that demand the highest dimensional accuracy. As a supplier of precision components, we deliver finished parts to your specifications and, upon request, also handle subsequent machining steps. Wire EDM, also known as wire cutting, has always been one of our core competencies and delivers precision down to the micro-detail. Every workpiece is produced on state-of-the-art wire EDM machines with the comprehensive expertise of our experienced team.
- Short Lead Times
- Any Material Thickness
- Nearly All Contours
- Wear-Resistant Parts
- TÜV-Certified Quality
- Experienced Team
Your Advantages
at a Glance.
When you choose to outsource wire EDM contract manufacturing to Condor® Custom Solutions, you benefit from these advantages.
Short Lead Times
You benefit from short waiting times and fast turnaround times.
Any Material Thickness
Even with substantial material thickness, we achieve extremely narrow kerf widths.
Nearly All Contours
Start-hole drilling machines and wire EDM machines produce simple as well as complex geometries.
Wear-Resistant Parts
The machined workpieces exhibit high resistance to wear.
Outsourcing
Can Pay Off.
Wire EDM contract manufacturing is worthwhile for companies that need precision EDM parts without operating their own equipment. A wire EDM machine ties up capital and requires maintenance as well as trained personnel. As a contract manufacturer, we provide this capacity to you on an as-needed basis.
No Capital Investment
You save the costs of purchasing, maintaining, and training for your own wire EDM system.
Modern Machine Fleet
You gain access to machines at the current state of the art.
Flexible Capacity
We manufacture individual parts as well as medium and larger series.
Focus on Core Business
You concentrate on your production while we handle the EDM work.
Reliable Wire EDM
at the Highest Level.
Condor® Custom Solutions offers reliable wire EDM at the highest level with maximum dimensional accuracy and fine surface finishes. We machine conductive materials regardless of their hardness, as hardness is not a limiting factor in wire EDM. Behind every workpiece stands the comprehensive expertise of our experienced team and the commitment to deliver consistent precision and repeatability. Our quality is TÜV-certified.
The Principle of
Electrical Discharge Machining.
Wire EDM is a material removal process in which a thin wire serves as the tool. The key points at a glance:
- Electrical discharge machining: Electrical sparks between the wire and workpiece remove material without contact, also known as electroerosion or EDM.
- No deformation: Without mechanical cutting forces, even delicate geometries remain dimensionally accurate.
- Requirement: The material must be electrically conductive.
- Angled cuts: Separately guided upper and lower wire guides enable conical contours.
- Accuracy: Tolerances in the range of a few thousandths of a millimeter, wire diameter typically 0.2 mm to 0.3 mm.
Suitable Materials: Conductive and of Any Hardness
Wire EDM is suitable for all electrically conductive materials, regardless of their hardness. These include the following material groups, among others.
Tool steel, hardened steel, stainless steel – wire EDM machines these steels regardless of their hardness, as the process removes material purely electrically. Ideal for hardened tool and mold components.
Copper, brass – highly conductive non-ferrous metals that can be eroded with precision and fine surface finishes. Frequently used for electrodes and electrical contact components.
Carbide, titanium, tungsten – extremely wear-resistant materials that are difficult to machine mechanically. Wire EDM removes them without contact, without stressing the tools.
Clean Results: Complex Geometries Without Rework
With start-hole drilling machines, we create the start hole for internal contours and then erode the finished form.
- Diverse geometries: Nearly all contours, simple and complex, manufactured quickly and economically.
- Clean edges: Sharp-edged, burr-free, and dimensionally accurate, with the smallest internal radii and fine surface finishes.
- Achievable accuracy: Dependent on material, material height, and geometry.
Typical Applications for Wire EDM
- Tool Making
- Mold Making
- Mechanical Engineering
- Measurement Technology
- Plant Engineering
- Automotive Technology
- Drive Technology
- Medical Technology
Typical Components for Wire EDM
- Cutting and Stamping Tools
- Mold Inserts
- Electrodes
- Gears
- Gauges and Sleeves
- Prototypes and Individual Parts
Wire EDM as Contract Work:
Your Order Process.
What our customers
say about us.
Condor has been our supplier for a long time. The short communication channels, technical expertise, and high technological standards are crucial for us.
We had almost given up on 3D printing for this product. Condor, through its excellent advice and high professionalism, helped us achieve series production.
Condor has been a supplier of precise mechanical components for mechatronic assemblies in our machines for many years.
Your Direct Path
to Us.
Let Condor® Custom Solutions handle your wire EDM contract manufacturing. Send us your drawing or CAD data, and you will receive a no-obligation quote for your component. Your dedicated contact person will personally guide your inquiry.
Frequently Asked Questions About Wire EDM
Wire EDM is suitable for all electrically conductive materials regardless of their hardness, such as tool steel, hardened steel, stainless steel, copper, brass, carbide, titanium, and tungsten.
Yes, wire EDM contract work is suitable for individual parts and prototypes as well as for medium and larger series.
No, wire EDM removes material without contact via electrical sparks, so no mechanical cutting forces act on the workpiece.
In wire EDM, a continuous wire cuts the contour from the workpiece, while in sinker EDM a shaped electrode is lowered into the material to create cavities and recesses.
Wire EDM machines material without contact and is therefore suitable for hardened and very hard materials that cause significant tool wear during milling. Additionally, fine internal contours and sharp internal corners can be produced that are difficult to achieve with rotating milling tools.
Costs depend on material height, cutting length, tolerance, material, and quantity. A reliable estimate requires an individual calculation for your component.