Ultra-fine wire EDM: machined parts with perfect angles and micron-level precision

What is Electrical Discharge Machining (EDM) and why does it guarantee perfect angles?

Electrical Discharge Machining (EDM) makes it possible to produce perfectly sharp and clean angles with an extremely small residual radius, something that is very difficult, or even impossible, to achieve using conventional machining methods such as milling or drilling.

EDM does not remove material through mechanical cutting, but through successive electrical discharges between an electrode and the workpiece, immersed in a dielectric fluid. As there is no direct mechanical contact with the material, no tool-induced residual radius is generated. This makes it possible to create sharp internal edges without rounding or residual radius, resulting in perfectly defined internal angles, including true 90° angles.
All applications, including high-precision micromechanics, can benefit from this technology.

Advantages of Ultra-Fine Wire EDM, Die-Sinking EDM, and EDM Milling at Mecasoft

At Mecasoft, our wire EDM technology uses a wide range of wire diameters, including ultra-fine wires, whereas most machines on the market rely on standard wire sizes. This allows us to machine highly technical and complex parts with sharp angles and no residual radius using ultra-fine wire EDM.
This technique enables micrometric machining of very small components with a flawless surface finish.

For die-sinking EDM, we shape the electrode with exact geometry to generate the form required for each project: square, pointed, complex, etc. This allows us to create complex electrode shapes with perfect angles, which are then used as a mold imprint to machine the final part geometry by EDM.

In addition to wire and die-sinking EDM, Mecasoft also uses EDM milling and micro-drilling (EDM fast drilling). A rotating electrode, typically following a fixed axis, removes material through micro-electrical discharges. Mecasoft also uses a 5-axis variant, combining the freedom of milling with the precision of EDM.

This technology makes it possible to generate complex 3D shapes while maintaining sharp internal edges and precise angles, even in geometries that are unreachable with traditional cutting tools. It is particularly relevant for deep cavities or mold impressions where angle sharpness directly impacts the quality and functionality of the final part.

Comparison: EDM, Laser Cutting, and Metal 3D Printing

Laser cutting technology can also achieve high precision. However, it involves significant risks of burrs or micro heat-affected zones along the edges. Laser cutting is also less competitive than EDM when machining very thick and highly complex parts.

Metal 3D printing offers an interesting alternative, providing great design freedom and fast production. However, its precision and surface finish quality remain inferior to those achieved with EDM. This is why EDM is frequently used as a complementary finishing technology alongside additive manufacturing.

For perfect internal angles, micron-level precision, and impeccable surface finish, Mecasoft’s ultra-fine wire EDM is unmatched.

Industrial Applications Where Micron-Level Precision Is Critical

Certain industries impose extremely high requirements when it comes to high-precision machining and micromechanics. Aerospace, aeronautics, watchmaking, mold manufacturing, pharmaceuticals, and medical devices are all fields where every angle, surface finish, and material choice can have a decisive impact.

In these environments, machining quality is not merely a matter of appearance, it directly affects reliability, safety, and product lifespan. Faced with these constraints, traditional manufacturing processes quickly reach their limits. This is where ultra-fine wire EDM cutting stands out as a state-of-the-art technology.
This micrometric machining technique delivers extremely precise cuts with perfect angles and micron-level tolerances, meeting the most stringent industrial standards.