What Is Wire EDM for Titanium? - Complete Guide
Complete guide to wire electrical discharge machining (EDM) of titanium alloys. Process capabilities, tolerances, surface finishes, lead times, cost ranges, and applications for precision titanium components.
Quick Answer
What is wire EDM for titanium?
Wire electrical discharge machining (EDM) uses a thin electrically charged wire to erode titanium through controlled spark discharges. It is ideal for producing precise contours, sharp internal corners, and burr-free features in hardened titanium components without applying cutting forces.
Capability
Wire EDM provides exceptional precision for titanium components with complex geometries. Key capabilities include:
- Burr-free cutting — no mechanical cutting forces, no burrs
- Sharp internal corners — radii down to 0.03 mm (wire radius)
- Taper cutting — up to 30° taper angles
- Through-hole and slot cutting — no pre-drilled start hole required (using EDM drilling)
- Stack cutting — multiple thin parts cut from stacked plate
- Minimum feature size — 0.2 mm slot width
- Maximum thickness — up to 500 mm
Tolerance
| Standard | Precision |
|---|---|
| ±0.002 mm | ±0.001 mm |
| ISO 2768-f | ISO 2768-m |
| Positional: ±0.005 mm | Positional: ±0.002 mm |
Tolerances are verified through first-article inspection and CMM reporting. Thermal compensation applied for long cuts.
Surface Finish
| Standard | Precision |
|---|---|
| 0.4 µm Ra | 0.1 µm Ra |
| 16 µin Ra | 4 µin Ra |
Multi-pass cutting (rough → trim → finish) achieves progressively finer finishes. Final skim pass at reduced power produces mirror-like surfaces.
Lead Time
| Phase | Duration |
|---|---|
| Prototype (1–10 pcs) | 3–5 business days |
| Low-volume (10–100 pcs) | 1–2 weeks |
| Production (100–1000+ pcs) | 3–4 weeks |
| Express service | Available on request |
Cost Range
| Complexity | Typical Range (per part) |
|---|---|
| Simple 2D profile | $50–$200 |
| Moderate (tapers, tight tol.) | $200–$800 |
| Complex (fine features, thick) | $800–$3,000+ |
| NRE (programming + setup) | $200–$1,000 |
Cost factors: part thickness, total cut length, number of pierce points, surface finish requirement, and material grade. Wire EDM is generally slower but more precise than conventional machining for equivalent features.
Recommended Materials
- Grade 5 (Ti-6Al-4V) — Aerospace components, medical instruments
- Grade 23 (Ti-6Al-4V ELI) — Implant blanks, surgical tooling
- Grade 9 (Ti-3Al-2.5V) — Thin-walled tubes, precision profiles
- Grade 2 (CP Ti) — Chemical processing components, gaskets
Applications
- Precision implant blanks for orthopaedic and dental applications
- Aerospace structural components requiring burr-free edges
- Semiconductor wafer handling end-effectors and grippers
- Medical cutting guides and surgical templates
- Thin-walled titanium components prone to distortion from conventional cutting
- Prototype and low-volume production of complex 2D profiles
- Slotted features, keyways, and precision holes in hardened titanium