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Sinker EDM Machining
Are you looking for super-precise cutting for your tough metals? Sinker EDM machining from Istar Machining is the answer! This special way of cutting can make complex shapes in the hardest metals. Let’s explore what makes it so amazing and how it can help with your projects.
- Making complex 3D shapes
- Cutting very hard metals
- Creating perfect molds and dies
- Making parts that need to be exact
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20+ Years
Istar Machining's years in the industry
300,000 square feet
The size of Istar Machining's factory
856 CNC machines
Our CNC equipment count
2000+ skilled workers
Istar's number of skilled machinists/operators
How Sinker EDM Works
Think of sinker EDM like using a cookie cutter, but with electricity! Here’s how it works:
- We make a special metal tool (electrode) shaped like the hole we want
- The tool gets very close to the metal but doesn’t touch it
- Electricity jumps between them, creating tiny sparks
- The sparks melt tiny bits of the metal away
- Special oil (dielectric fluid) washes away the melted bits
- This happens thousands of times until the perfect shape is made
The best part? This works on super hard metals that regular cutting tools can’t handle!
Materials We Machine with Sinker EDM
Our sinker EDM process works with many tough metals:
Steels
Aluminum Alloys
Copper Alloys
Titanium Alloys
Nickel Alloys / Superalloys
Carbides
Exotic and Refractory Metals
Steels
From common alloys to the toughest hardened tool steels, Sinker EDM provides precision and excellent surface finishes.
Carbon Steels: (e.g., 1018, 1045)
Alloy Steels: (e.g., 4140, 4340)
Tool Steels: (Crucial for EDM; Ideal for molds, dies, and high-wear components)
- A2, D2, H13, S7, P20, O1, M2, M4, PM Grades (e.g., CPM-10V)
Stainless Steels: (All conductive series)
- Austenitic (e.g., 303, 304/304L, 316/316L)
- Martensitic (e.g., 410, 420, 440C)
- Precipitation Hardening (e.g., 17-4 PH, 15-5 PH)
Pre-hardened Steels: (e.g., P20, H13 hardened condition)
Case Hardened Steels: (After hardening)
Aluminum Alloys
Lightweight, versatile, and easily processed using Sinker EDM for various applications.
Common Wrought Grades: 6061, 7075, 2024, 5052
Tooling Plate: MIC-6, Alca-5
Cast Aluminum Grades: (e.g., A356, A380)
Copper Alloys
Excellent electrical conductivity makes copper and its alloys suitable workpieces, often used in electrical and thermal applications.
Copper: C101 (OFE/OFHC), C110 (ETP)
Brass: C360 (Free-Cutting Brass)
Bronze: C932 (Bearing Bronze), C954 (Aluminum Bronze)
Beryllium Copper (BeCu): C172, C173 (Often used for mold inserts requiring high strength and thermal conductivity)
Titanium Alloys
Known for high strength-to-weight ratio, biocompatibility, and corrosion resistance; often challenging for conventional methods but ideal for Sinker EDM.
Commercially Pure (CP): Grade 1, Grade 2, Grade 4
Alpha-Beta Alloys: Grade 5 (Ti-6Al-4V) – Most common
Beta Alloys: (Various grades)
Nickel Alloys / Superalloys
High-performance alloys designed for extreme temperature, pressure, and corrosive environments. Sinker EDM effectively handles their inherent toughness.
Inconel®: 625, 718, X-750
Hastelloy®: C276, C22, X
Monel®: 400, K500
Waspaloy®
Rene Alloys (e.g., Rene 41)
Carbides
Extremely hard and wear-resistant materials where Sinker EDM is often the only viable machining method for creating complex shapes or features.
Tungsten Carbide (WC)
Cemented Carbides (Various Cobalt or Nickel binder grades)
Exotic and Refractory Metals
We have experience machining materials with unique properties like very high melting points, density, or extreme hardness.
Tungsten (W)
Molybdenum (Moly)
Tantalum (Ta)
Niobium (Nb) (also known as Columbium)
Cobalt Chrome (CoCr) (e.g., ASTM F75, F1537 – often used in medical implants)
Technical Details That Matter
Product Parameters | What It Means For You |
Power Supply: 30-50A (rough cutting), 3-10A (finishing) | We can cut fast for rough shapes, then switch to super-precise finishing |
Electrode Materials: Graphite, Copper-Tungsten, Brass | We choose the perfect electrode for your project’s needs |
Orbital Machining: 0.1-3mm offset control | We can make undercuts and complex angles that other methods can’t |
Dielectric Fluids: Hydrocarbon oil, Deionized water | The right fluid ensures clean, precise cuts on your specific metal |
Surface Finish: Ra 0.8–3.2 µm | Get surfaces smooth enough to use with minimal polishing |
Precision: ±0.0001″ (2.5µm) | Parts that fit perfectly every time |
CNC Products Produced by Istar Machining
Industries We Serve With Sinker EDM
At Istar Machining, we help many different industries with our sinker EDM services:
Automotive
We make perfect die components and transmission gears that last longer and perform better. Want to learn more? Check out our automotive CNC machining page.
Medical
Our sinker EDM process creates the tiny, complex parts needed for biocompatible implants and microfluidic devices. We maintain strict cleanliness standards for all medical parts.
Aerospace
Fuel nozzles and heat-resistant shrouds for jet engines need to be perfect. Our aerospace EDM services meet or exceed all industry standards.
Consumer Electronics
We make perfect injection molds for tiny connectors and electronic housings. These molds create consistent parts for millions of cycles.
Key Applications of Sinker EDM Machining
Sinker EDM is perfect for many different industries. At Istar Machining, we help customers with:
Mold & Die Manufacturing
We make perfect molds for plastic injection, metal stamping, and forging. Our precision CNC machining service paired with sinker EDM creates flawless molds that last longer.
Aerospace Components
Aerospace parts need to be perfect. We make turbine blades and fuel system parts that meet the strictest standards. Our ±0.0001″ tolerances mean parts that fit perfectly every time.
Medical Devices
For medical tools and implants, we create the tiny, complex shapes doctors need. Our clean processes ensure parts meet all health standards.
Tiny Holes Without Threads
We can make super small holes (as small as 0.008″ wide) without damaging the metal. This is great for precision parts and microfluidic devices.
Fixing Old Tools
Have an old die or mold that’s worn out? We can use sinker EDM to fix it without making a whole new one – saving you money!
Why Choose Istar Machining for Sinker EDM?
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5-Axis Precision
Our advanced machines can control the spark gap and orbital paths to create undercuts and complex angles that other shops simply can't make.
Combined Technologies
We can mix sinker EDM with our wire EDM machining and CNC milling for multi-feature parts that would be impossible to make any other way.
Faster Production
Our adaptive flushing systems reduce cutting time by 25% compared to standard methods. This means you get your parts faster without sacrificing quality.
Material Expertise
We have partners who provide certified aerospace and medical-grade alloys. This means we can help you choose the right material for your project.
Zero Defect Promise
We follow ISO 9001 standards and provide full documentation of your parts. You'll know exactly what you're getting.
The Sinker EDM Process at Istar Machining
Design Review
We look at your design to make sure it's perfect for EDM.
Electrode Making
We carefully create the electrode that will shape your part.
Test Cuts
We make sample cuts to verify dimensions before full production.
Production
Your parts are made with constant monitoring for quality.
Inspection
Every part is checked against your specifications.
Frequently Asked Question
Sinker EDM (also called Ram EDM or Die-Sinking EDM) is a thermal erosion process that uses electricity to cut metal. It doesn’t touch the metal directly. Instead, it creates tiny sparks that melt away small bits of metal.
Different projects need different electrodes:
- Graphite: Great for rough cutting (cost-effective)
- Copper-tungsten: Perfect for fine details
- Brass: Works well for high-speed drilling operations
Sinker EDM is best for making deep cavities and blind holes. Wire EDM works better for cutting all the way through material in 2D shapes. At Istar Machining, we often use both methods on complex parts.
Yes! We use powder additives in our dielectric fluid that can reduce roughness by 50%. This means less hand finishing later.
We make multiple electrodes at once and use automated tool changers to keep costs down. Let us know your budget, and we’ll find ways to help you save.
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