Four-Axis Fast Wire EDM Streamlines Mold Insert Removal

EDM Network is featuring its large-format fast wire EDM, the Edmmax818W, which was developed to accommodate very large builds — up to 1.5 meters high on top of build plates 6" or more. It is useful for 3D printed metal removal on parts like mold inserts, such as those printed on the Matsuura Lumex Hybrid metal 3D printer/hard mill above. The work enclosure is 78" × 43" × 33" with a weight capacity of 6,000 Ibs. The X Y and Z travels are 800 × 1,000 × 800 mm respectively. Taper capability is also included.

The Edmmax818W is a full four-axis wire EDM that, is addition to cutting 800 × 800-mm build plates, can also be used for traditional wire EDM applications like tall keyways, gears, splines, molds, dies fixtures and special tooling in hard metals. 

Fast wire EDMs are known for their use of high tensile 0.007" molybdenum wire instead of brass. In addition, it continuously reuses the 250 meters of wire for up to 100 hours depending on the workpiece type and thickness; the wire costs about $20, i.e., about $1/hour total operating cost.

The wire feeds from a spool, through the rollers, then through the lower diamond wire guide, through the workpiece, the upper diamond wire guide, then back to the spool, so it is attached on both ends. Then, during the cutting process, the wire feeds through the workpiece at 5 m/sec until it reaches the end, at which time it reverses direction back through the workpiece until it is finished. This fast-moving wire creates its own flushing to remove swarf. It does not require high water pressure or submerging to achieve fast cutting. Because it does not require high pressure water, EDM Network says it can cut the interrupted cuts of a 3D print, or any terrible flush condition, without breaking the wire. Typically in bad flushing, these fast wires will cut three to five times faster than a traditional wire EDM.

The Edmmax818W also features a built-in CAD system, maintains USB and LAN ports for Dxf files, has AC and DC switchable power to handle all metals and comes with on-site operator training.