Aerospace EDM Service

What is Aerospace EDM Machining?

EDM (Electrical Discharge Machining) uses tiny electric sparks to cut metal. This works great for aerospace components that:

• Need to be super accurate (within ±0.0001″)
• Are made from very hard metals
• Have complex shapes that regular cutting can’t make
• Must have no burrs (rough edges)

Our sinker EDM machining service makes perfect parts every time!

Why Aerospace Companies Choose Our EDM Machining

Materials We Master with Aerospace EDM

Our team at Istar Machining works with all the special metals needed for flight:

• Titanium (Ti-6Al-4V): For strong but light parts
• Inconel 718 & 625: For extreme heat resistance in engines
• High-temperature superalloys: For the hottest areas of aircraft
• Stainless steel & carbides: For durable structural components

Our titanium CNC machining capabilities complement our EDM processes for complete solutions.

Real-World Uses of Our Aerospace EDM Machining

Istar Machining delivers precision parts for these critical aerospace applications:

• Turbine blades with perfect cooling channels (±0.0001″ tolerance)
• Fuel nozzles with micro-sized holes that never clog
• Engine components that withstand extreme heat
• Structural brackets that are lightweight but super strong
• Flight control parts with zero burrs for smooth movement
• Avionics housings that protect sensitive electronics

We make these with our 5-axis machining capabilities combined with advanced EDM.

Our Advanced EDM Capabilities

Istar Machining offers two main types of EDM for aerospace:

1. Wire EDM

• Uses a thin wire (as small as 0.004″) to cut through metal
• Perfect for making fuel system holes and complex 2D shapes
• Can cut any conductive material no matter how hard
• Makes parts with no burrs that need no finishing

2. Sinker EDM

• Creates deep cavities and complex 3D shapes
• Ideal for mold tooling and internal cooling channels
• Makes perfect internal corners impossible with regular cutting
• Produces mirror-like surface finishes (Ra <8 µin)

Quality That Meets Aerospace Standards

When you work with Istar Machining, your parts get:

• AS9100 certification: The gold standard for aerospace
• ITAR compliance: For defense projects
• CMM inspection: We check every dimension
• NDT testing: We verify material integrity
• Material traceability: We track every piece of metal
• Burr-free results: No sharp edges to cause problems

Why Choose Istar Machining for Aerospace EDM?

1. Proven expertise: We work with major aerospace companies
2. Speed: We can deliver urgent parts when you need them
3. Complete service: From prototype to production
4. Problem solvers: We help with design for manufacturability
5. Scalability: From single parts to thousands of units

Our aerospace CNC machining services combine with our EDM capabilities to deliver complete solutions.

From Prototype to Production

Istar Machining supports you through every stage:

• R&D Prototypes: Test your ideas quickly
• Qualification Units: Verify your design meets standards
• Low-Volume Production: For limited runs of specialty parts
• Production: Consistent quality for ongoing needs

We use modular production cells that can scale from 10 to 10,000 units with the same quality.

Industries We Serve

Our aerospace EDM machining helps these sectors:

• Commercial Airlines: Passenger jet components
• Military Aircraft: Defense systems and structures
• Space Exploration: Satellite and launch vehicle parts
• Defense Contractors: Mission-critical components
• Aviation OEMs: Original equipment for new aircraft

Get Your Aerospace Parts Made Right

Istar Machining delivers:

• Burr-free, flight-ready parts
• AS9100 compliance guaranteed
• Expert engineering support
• Fast quotes and turnaround

Contact us today to learn how our aerospace EDM services can solve your toughest manufacturing challenges!