Electrical discharge machining is generally capable of processing any conductive materials. Some materials, including aerospace-grade high-nickel alloys, can be difficult to machine. However, the solution is frequently altering the electrode material or machining speed. The electrode’s conductivity and erosion resistance are the key factors that influence electrode material selection.

EDM has a very tight tolerance range of +/- 0.012mm, which is why it is highly preferred in the aerospace and medical industries.

The cutting speed and surface finish quality are balanced, like any other machining method. It is typical for the first cut to be faster and rougher, followed by slower cuts that provide a cleaner surface finish. More tool passes can be made at slower speeds to get a smooth surface polish, which can increase the machining process and costs.

Electrical machining can be used for the following purposes:

• Cutting rotary forms
• Drilling curved holes
• Engraving on hard materials
• Removing faulty tools from workpieces
• Drilling small holes
• Cutting sharp internal corners
• Making injection molding tools
• Cutting extrusions
• Removing broken devices from workpieces