How Wire Erosion Achieves ±/-5 Micron Precision: A Deep Dive
Known for its exceptional accuracy, Wire Erosion / Wire EDM enables us to achieve tolerances as tight as ±/-5 microns.
At H V Wooding, we’ve spent nearly 40 years perfecting our wire erosion processes to meet the most demanding engineering standards. Known for its exceptional accuracy, Wire EDM (Electrical Discharge Machining) enables us to achieve tolerances as tight as ±/-5 microns — a feat that few manufacturing methods can match.
At H V Wooding, we’ve spent nearly 40 years perfecting our wire erosion processes to meet the most demanding engineering standards. Known for its exceptional accuracy, Wire EDM (Electrical Discharge Machining) enables us to achieve tolerances as tight as ±/-5 microns — a feat that few manufacturing methods can match.
But how does wire erosion reach such extreme levels of precision? Let’s take a closer look at the science, process control, and quality assurance that make it possible.
What Does ±/-5 Microns Actually Mean?
To put it into perspective, a human hair is approximately 100 microns in diameter. Achieving a tolerance of ±5 microns means your component’s dimensions are accurate to within 5% of a hair’s width — both sides. That level of control is essential in industries such as aerospace, medical, motorsport, and electric motors, where micro-level deviations can compromise performance or reliability.
The Wire EDM Process: Precision by Design
Wire erosion doesn’t rely on physical cutting or pressure. Instead, it uses a strand of electrically charged wire (usually brass or zinc-coated) to create a series of controlled electrical discharges (sparks) between the wire and the conductive workpiece.
Key Factors That Enable High Precision:
-
No mechanical contact: Since no cutting tool touches the part, there’s zero mechanical stress or deformation, allowing for precise cutting of thin, fragile, or delicate components.
-
Submerged cutting: At H V Wooding, we use submerged wire EDM which offers better thermal stability, improved debris flushing, and consistent spark control — all contributing to accuracy and repeatability.
-
CNC control: Computer-programmed movement allows for highly detailed and repeatable geometries, even on complex profiles.
-
Automatic wire feeding: Ensures consistent tension and feed rate, maintaining cut precision over long and complex runs.
The Importance of Metrology in Wire Erosion
At H V Wooding, precision doesn’t stop when the machine does. Every wire-eroded component is measured and validated using high-resolution metrology equipment:
-
CMM (Coordinate Measuring Machine) for dimensional accuracy
-
Quick Scope optical inspection for rapid, non-contact measurement
-
SPC & FMEA processes to ensure consistent quality across batches
Combined with our ISO 9001, 14001 and 45001 certifications, this commitment to quality gives customers full confidence in every part we deliver.
Why Experience Matters
Wire EDM is not just about the machine — it’s about how you use it. With nearly 40 years of experience, we’ve evolved our processes to support everything from one-off prototypes to multi-layer production runs for global OEMs. Our operators and engineering team understand the nuances of electrode wear, spark gap compensation, flushing pressures, and how to adapt to complex geometries — all of which influence micron-level tolerances.
Real-World Example: CERN’s Large Hadron Collider
One of our most demanding projects involved manufacturing sub-5 micron tolerance steel yokes for CERN’s Large Hadron Collider. These components were used in high-energy physics experiments where dimensional accuracy under load and temperature variation was non-negotiable.
Summary: Precision You Can Rely On
Wire erosion’s ability to achieve ±5 micron tolerance makes it indispensable in today’s high-tech industries. At H V Wooding, we combine advanced equipment, expert operators, and robust quality systems to ensure your most complex components are delivered to spec — every time.
If you have a project requiring exceptional precision, or want to explore whether wire EDM is right for your application, we’re here to help.
