With over 100 years combined experience and the latest state-of-the-art software and equipment, HDT’s EDM technicians are among the best in the industry. Our team has provided high-quality EDM manufactured products to clients in a variety of major markets including automotive, aerospace, defense, medical, and agriculture to name a few. Our machine capacity can handle parts ranging from .040” in diameter to 20” x 30” x 14” with the ability to offer surface finish control without compromising structural integrity. The knowledge and expertise of our certified EDM technicians is second to none. Our team looks forward to a challenge and the chance to demonstrate the extraordinary craftsmanship that can be achieved through skilled EDM manufacturing.

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Electrical Discharge Machining is an advanced machining technique that allows for precise, detailed cuts that were once thought to be out of reach with traditional machining. Years ago, EDM machining was used mainly for mold-making, however it has now become a crucial part of tool making especially for prototype and production work. With the ability to repeatedly and consistently complete parts with minute tolerances, EDM machining has become the ideal solution for manufacturing parts with unique cuts, angles, tolerances and materials. Materials used in the EDM process must be electrically conductive such as copper, aluminum, bronze, tungsten, carbon steel, high alloy, Inconel, Hastelloy, medical grade stainless steel or carbon graphite.

​Header Die & Tool employs three types of EDM technologies in an effort to offer our customers the best solution for their machining needs.

WIRE EDM

The Wire EDM process is achieved by creating an electrical discharge between the wire and the workpiece. A spark is sent from the shortest distance between a single strand of wire, usually brass, and the workpiece where it jumps the gap (known as the spark gap) at which point material is burned away from the workpiece. In order to control the sparking process from shorting out, dielectric, a non-conductive fluid solution is used to either flush or submerge the entire Wire EDM process. The eroded waste material is removed by the continuous flow of the dielectric fluid which is cooled and filter throughout the entire process. Since Wire EDM is mainly used for cutting shapes through assemblies and inserts, it is usually necessary to predrill a hole for the wire to be fed through in order for machining to be completed. The Wire EDM process is utilized only when the required cut goes through the entire workpiece.

BENEFITS OF WIRE EDM

• Precision cuts; Wire EDM accuracy can be within +/- .0003”
• Internal corner cuts with nearly square edges
• Ability to cut long tapers that would otherwise be impossible
• More accurate production & prototype runs with shorter lead times
• Capability to accurately and repeatedly machine delicate & intricate parts with no deflection
• Wire EDM does not generate burrs
• Does not require tooling
• Ability to machine pieces up to 12″
• Machining takes place after heat treatment so dimensional accuracy is not affected by heat treat distortion

WIRE EDM SPECIFICATIONS & CAPABILITIES

• Maximum angle for taper is 45°
• Maximum cutting height is 16.5”
• Tolerance can be maintained to .0003”
• Wire Diameters from .002”-.010”
• Materials from copper, bronze, tungsten, carbon steel, high alloy, Inconel, hast alloy, stainless steel or carbon graphite
• Maximum weight for workpiece: 1800 lbs.
• Maximum angle: +/- 10° at 12” thick workpiece; 30° at 3.25” workpiece; 45° at 1.93” workpiece
• Maximum travel: X=21.7”, Y=14.6”, Z=12.2”