Wire EDM Titanium for Precision Slots and Thin-Wall Components

Background: Precision Slot and Thin-Wall Requirements

Thin-wall titanium components are widely used in aerospace, medical, and high-end industrial applications. These parts often feature narrow slots, sharp internal corners, and delicate structures that are difficult to achieve with conventional cutting methods.

In this case, the customer required titanium components with ultra-precise slots and minimal deformation. Wire EDM titanium machining was selected to achieve the required accuracy while maintaining structural integrity.

Material Selection and Machinability Challenges

Titanium alloys were selected due to their strength, corrosion resistance, and dimensional stability. However, machinability challenges included:

• Heat sensitivity during conventional cutting

• Risk of deformation in thin-wall sections

• Difficulty producing sharp internal features

Wire EDM titanium processing eliminates cutting forces, making it ideal for complex geometries and fragile structures.

Wire EDM Titanium Machining Process

The wire EDM process included:

• Precision programming of cutting paths

• Controlled electrical discharge to remove material

• Minimal thermal impact on surrounding material

EDM titanium machining produced clean edges, consistent slot widths, and high dimensional accuracy.

Integration with CNC Titanium Machining

After EDM cutting, CNC machining was applied for:

• Face milling reference surfaces

• Drilling and tapping assembly holes

• Final dimensional refinement

This hybrid approach ensured both precision and functional integrity in machined titanium parts.

Dimensional Accuracy and Surface Quality

Critical dimensions were controlled within ±0.01 mm. Slot geometry, parallelism, and flatness met strict specifications. Surface integrity was preserved, with no burrs or mechanical stress marks.

Inspection and Quality Control

Inspection methods included:

• CMM measurement of slot width and position

• 100% visual inspection

• Gauge verification for thin-wall thickness

These inspection steps ensured consistency across all CNC titanium parts.

OEM and Engineering Collaboration

Engineering teams worked closely with the customer to:

• Optimize EDM cutting sequences

• Reduce material stress during machining

• Validate prototypes before batch production

Design and programming tools included CAD, CAM, and CAE software. Supported formats included STEP, DWG, DXF, IGS, STL, and PDF.

Applications of Wire EDM Titanium Parts

Wire EDM titanium machining is commonly used for:

• Aerospace thin-wall brackets

• Medical device precision components

• High-tolerance industrial assemblies

This process enables complex shapes that are difficult or impossible with traditional cutting methods.

Conclusion

This case demonstrates how wire EDM titanium machining, combined with CNC titanium machining, delivers exceptional precision for thin-wall and slot-intensive components. By addressing titanium machinability challenges and using advanced inspection methods, high-quality machined titanium parts were achieved for demanding applications.