For metalworkers requiring extreme precision in cutting workpieces, wire electrical discharge machining (wire EDM) has long been a technology of choice. Recently, however, wire EDM technology has become even more refined with the development of advanced systems that can cut workpieces to an accuracy of half a micron, a measurement equal to one-millionth of a meter.

One such precise wire EDM system, the Agiecut Vertex, developed by Agie USA Ltd., Davidson, NC, resembles a high-end measuring machine with the addition of a couple of key elements to its design. First, the actual work zone is kept as close to the machine's axis motion as possible and far away from heat and vibration. Also, the machine is designed to be very compact in order to decrease the influence of any outside factors. Furthermore, the unit that feeds the cutting wire can switch back and forth between two sets of wire that measure between 0.02 to 0.20mm (0.008 to 0.0008 of an inch). This unit can be programmed to cut with one size wire and then automatically switch to the wire in the other spool. Cuts made with the first wire can be given an instant refinishing with its 0.02mm counterpart to give corners an extremely small corner radius or give an ultra-fine surface finish to a workpiece. The machine tool, wire feed unit, control unit and power supply are all contained within the unit's enclosure. Manufacturers of electronics, computer chips, time-keeping equipment, medical devices and micro-mechanical parts all stand to benefit from wire EDM systems that cut with submicron accuracy such as Agie's new machine.

Although further precision using the wire EDM process is theoretically possible, the current level of precision has seemed to set the standard for the near future.

Source: Machining to Sub-Micron Accuracy – With EDM
Mark Albert
MMS Online, Nov. 1, 2001
http://www.mmsonline.com/articles/1101rt1.html