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i3D MFG™ Electronic Discharge Machining

EDM

Wire Electronic Discharge Machining (Wire EDM)

Electrical Discharge Machining (EDM), also called spark machining, spark eroding, or wire erosion, is a precision manufacturing process through which, a desired shape is cut to held tolerances of up to +/- .001mm using electrical discharges across a fine wire. i3D MFG™ utilizes the precise CUT 30P’s strict tolerances to remove parts from its DMLS build plates.

Many of our customers have found that there are less complex, but high tolerance parts that are well-suited to production on the Wire EDM. With minimal set-up time for intricate cutting patterns, the CUT 30P is a perfect complimentary manufacturing process.

Material is removed from the base stock through a series of rapidly recurring current discharges between two electrodes (the ‘tool’ electrode and the ‘work-piece’ electrode), separated by a dielectric liquid and subject to electric voltage.

Key Statistics:

  • Wire diameters from 0.15mm to 0.30mm
  • Accuracy of up to .001mm
  • Conductive materials to any hardness (i.e. steel or titanium)
  • Surface finish as fine as 5 microns

Agie Charmilles Cut 30P

Electrical Discharge Machining

The Agie Charmilles CUT 30P Wire EDM cutting machine is equipped with joint technology from GF Machining Solutions and Agie Charmilles, the market leaders in precision cutting and finishing solutions. The CUT 30P uses fine wire ranging from 0.15mm to 0.30mm (0.006in to 0.012in) and is highly flexible in its ability to satisfy engineering and production requirements commonly called for in standard stamping.

Its on-board software technologies allow unique speed cuts, optimizing main, 2nd and 3rd finishing cuts, and resulting quick production of common surface roughness requirements (ie: Ra 0.60 μm (24μin) and Ra 0.35μm (14μin)). Its high speed technologies make the CUT 30P a powerful complimentary process and competitive advantage for i3D MFG™ customers.

Key Statistics:

  • Handles wire diameters ranging from 0.15mm to 0.30mm
  • Accuracy of up to one-thousandth of a millimeter (.001)
  • Conductive materials to any hardness
  • Surface finish as fine as 5 microns

Metals We Print

i3D MFG™ offers one of the largest selections of DMLS standard metal powders in the U.S. We are one of the few 3D manufacturers specializing in Titanium and Inconel and are the EOS North America MPA (Material Process Applications) partner specializing in custom metal powder applications. Our engineers are experts in Design-for-3D strategies, enabling our customers to realize significant competitive advantages in design and proprietary advancements.

Visit Our DMLS Library

Aluminum (Al)

AlSi12 is our most common DMLS Aluminum powder and is perfect for projects with good thermal and low weight considerations.  It is an optimal metal for parts with thin walls and complex geometries.

Titanium (Ti)

Ti64 is the standard DMLS powder which is well suited for Medical, Aerospace, Firearms, Energy and Automotive projects requiring corrosion resistance, strength, weight reduction and biocompatibility.

Stainless Steels

PH1 is a medical grade, sterilisable, corrosion resistant steel. It is primarily used in Medical, Firearms, Energy and Automotive applications. After heat treatment, PH1 hardens to 40-45 HRC. Our stainless steel equivalents include 15-5, 17-4, and .316. Parts made from EOS StainlessSteel PH1 can be machined, spark-eroded, welded, micro shot-peened, polished and coated if required.

Maraging Steel

Our maraging steel powder has excellent strength and mechanical properties. MS1 is a pre-alloyed, ultra high strength steel powder most commonly used for tooling applications. Its chemical composition corresponds to U.S. 18% Ni Maraging 300, European 1.2709 and German X3NiCoMoTi 18-9-5. After heat treatment, MS1 typically has a 50-53 HRC.

Inconel (IN718)

IN718 is a DMLS nickel; A Chromium alloy with superior heat resistance and typical heat treatment hardness of 40-47 HRC (370-450HB).  Rocket, space, aerospace, firearms, energy, and automotive industries rely on Inconel.

Custom Powders

i3D MFG™ is the market leader is DMLS powder development. In addition to our established metallurgical partnerships, i3D™ is the first North American EOS Material Process Application (MPA) Development Partner, giving us access to the latest DMLS machine parameter sets and enabling i3D™ to develop highly specialized powder applications for aerospace, rocket, automotive, and casting customers.

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