Wire EDM Machining Services
Electric discharge cutting for micro-slots, hardened titanium alloys, thin-wall parts, and complex tapered profiles — achieving ±0.002 mm accuracy and Ra 0.25 µm micro-finish.
Wire EDM Process Advantages
Electric discharge cutting offers unique capabilities for titanium that conventional machining cannot match — zero force, unlimited hardness, and microscopic corner radii.
Zero Mechanical Stress
No Physical Tool ContactUnlike conventional milling or turning, wire EDM uses electrical discharge erosion — eliminating cutting forces entirely. Ideal for ultra-thin wall titanium structures that would deform under mechanical tool pressure.
- No cutting forces — ideal for thin-wall titanium parts down to 0.2 mm wall thickness
- Zero tool deflection or chatter — maintains ±0.002 mm accuracy on every contour
- No workpiece clamping distortion — only minimal electrical contact required
- Eliminates pre-hardening machining steps for thin-wall components
Sharp Internal Corners
Ultra-Fine Electrode Wire ø 0.1 mmUtilizing electrode wire diameters down to 0.1 mm (0.004"), our wire EDM machines achieve near-zero radius internal corners — impossible for any rotating cutting tool to produce.
- Internal corner radii down to 0.05 mm — limited only by wire diameter
- No tool clearance requirements — cut deep cavities with parallel walls
- Multiple passes achieve Ra 0.25 µm surface finish on vertical walls
- Tapered cutting up to ±30° for complex draft-angle geometries
Hardened Titanium Mastery
Post-Heat-Treatment ProcessingWire EDM's erosion-based process is independent of material hardness or toughness. We can cut fully hardened titanium alloys (48+ HRC) that would destroy carbide tooling — with the same precision as annealed stock.
- Cuts fully heat-treated titanium (48+ HRC) without tool wear concerns
- No post-cut burrs, recast layers, or heat-affected zones requiring secondary deburring
- Eliminates pre-machine/heat-treat/finish cycles — consolidate operations
- Ideal for hardened spring steels, nitrided surfaces, and carbide-tipped inserts
Wire EDM Machine Dashboard
Physical machine boundaries of our wire EDM platforms — calibrated for titanium aerospace and medical precision standards.
Max Workpiece Envelope
Generous work tank accommodating medium-to-large titanium components, aerospace structural frames, and medical implant blocks.
Maximum Taper Angle
High-precision taper cutting for aerospace impeller vanes, turbine blade roots, and tapered slots — achieved with U/V axis travel compensation.
Extreme Accuracy
Linear positioning precision achieved through glass-scale feedback, thermal compensation, and multi-pass skim cutting routines.
Micro Surface Finish
Ultra-smooth finish achieved through multi-pass skim cutting with progressively lower discharge energy — eliminating secondary polishing operations.
Specifications apply to our Sodick / Mitsubishi wire EDM platforms. Actual results depend on material thickness, part geometry, and number of skim passes.
Controlling Titanium's EDM-Specific Challenges
Titanium's metallurgical response to electrical discharge machining requires precise control of thermal, chemical, and fluid dynamics. Here's how we ensure fatigue-safe, oxidation-free EDM surfaces.
"White Layer" Suppression
During wire EDM of titanium, the intense localized heat (10,000°C+) from electrical discharge creates a recast layer — a brittle, re-solidified 'white layer' on the cut surface. This micro-cracked layer acts as a fatigue initiation site, reducing component lifespan by up to 40% in cyclically loaded aerospace and medical implants.
Multi-Pass Skim Cutting & Anti-Electrolysis Micro-Pulse Power Supplies
- First rough-cut pass removes bulk material at high speed, followed by 3-5 skim passes with progressively lower discharge energy (from 5 A down to 0.5 A) — removing the recast layer in controlled increments of 5-15 µm per pass
- Anti-electrolysis micro-pulse generators (pulse width < 1 µs) prevent galvanic corrosion at the wire-workpiece interface, suppressing the electrochemical dissolution that contributes to white layer depth
- Final finish pass at ultra-low energy (0.1-0.5 A) achieves recast-free surface with Ra 0.25 µm — eliminating secondary polishing or chemical etching operations
- White layer thickness verified via metallographic cross-section examination per ASTM E3 — consistently < 2 µm on production parts, zero micro-cracking at 500× SEM inspection
Fluid Contamination & Oxidation Control
Titanium's high chemical reactivity at elevated temperatures (above 600°C) causes rapid oxidation and discoloration during the EDM spark discharge. Contaminated dielectric fluid — carrying suspended erosion debris — further degrades surface quality, causing pitting, uneven recast, and color banding visible on the cut surface.
Closed-Loop Deionized Water Resistivity Monitors & Nano-Filtration Systems
- Real-time dielectric resistivity monitoring (target 10-20 µS/cm for titanium) with closed-loop control — automated deionization resin regeneration maintains consistent fluid purity throughout extended EDM runs
- Multi-stage nano-filtration (1 µm absolute) removes 99.9% of suspended erosion debris from the dielectric fluid — preventing particle re-deposition on the cut surface that causes pitting
- Chilled dielectric circulation (20-25°C ±1°C) maintains stable thermal conditions in the spark gap, preventing localized boiling that would introduce oxygen to the cut zone
- Surface oxidation verified via visual inspection per ASTM B117 and EDS elemental analysis — consistently silver-gray appearance across entire cut surface, no blue/gold discoloration bands
EDM Broaching & Sinker EDM
Two complementary EDM modalities solve internal-form and blind-cavity geometries that milling cannot reach — with the same surface-integrity rigor as our wire cutting.
EDM Broaching
Producing splines, keyways and square/hex bores in titanium traditionally requires broach tooling or single-point machining. Titanium's work-hardening and low thermal conductivity cause rapid tool wear, poor surface finish and inconsistent form accuracy.
Our SolutionWire EDM broaching cuts the internal form directly from a pilot hole — no dedicated broach tool, no tool wear, and ±0.005 mm form repeatability with a fatigue-safe, recast-minimized surface on the finished tooth profile.
Sinker (Ram) EDM
Blind cavities, 3D contoured pockets and internal features in hardened or difficult-to-machine titanium parts cannot be reached by conventional milling without deep-tooling and excessive heat build-up.
Our SolutionSinker EDM uses graphite and copper-tungsten electrodes with adaptive multi-phase flushing to erode precise cavities and contours while controlling the recast layer and preserving dimensional accuracy on complex geometries.
Need Precision Narrow Profiles?
Submit Your Wire EDM Drawings
Upload your STEP, IGES, or PDF engineering files for a complete 24-hour manufacturing feasibility assessment — including taper angle analysis, achievable corner radii, surface finish optimization, and multi-tier pricing.
Submit for DFM AnalysisGuidance for the professionals who specify titanium
Role-specific answers and resources for engineers and buyers in this industry.
Common questions from this audience
What titanium CNC machining services do you offer?
3/5-axis milling, CNC turning and mill-turn, wire EDM, and custom industrial components — from rapid prototyping to high-volume production.
What tolerances can you hold on machined titanium?
We hold tolerances down to ±0.005 mm with 3/5-axis machining and in-house CMM inspection.
Do you provide DFM feedback before quoting?
Yes—our engineers review your drawings or CAD and provide DFM feedback with a quote, typically within 24-48 hours.
Related resources
Request a quoteOne Metal. One Focus. Infinite Precision.
Founded in 2011 in Baoji's Titanium Valley, BOZE Metal is dedicated exclusively to titanium — from raw material to precision engineering. AS9100D, ISO 13485 & ISO 9001 certified with 500+ clients across Aerospace, Medical & Motorsport industries, we deliver end-to-end precision titanium CNC machining with full material traceability from source to component.
Boze Titanium Manufacturing Center is operated by Baoji Boze Metal Products Co., Ltd.