Welcome to the Microtec EDM blog, where precision meets innovation. Microtec EDM is a UK-based specialist in electrical discharge machining (EDM), offering expert Wire EDM and Micro EDM services for a diverse range of industries including Defence, Medical, Aerospace, Motorsport, and more. With over 20 years of experience, we pride ourselves on delivering high-quality, precision-engineered components to meet the exacting standards of our clients, backed by inspection & quality control services.
In this blog post, we’ll explore the crucial role that inspection and quality control play in Wire EDM processes. We’ll begin by explaining what Wire EDM is and how it works, then delve into the significance of rigorous inspection and quality assurance, highlighting the advanced capabilities of Microtec EDM. Finally, we’ll discuss how Microtec can assist your business in achieving flawless components with uncompromised quality. Get in touch with us today for more information!
What is Wire EDM, and how does it work?
Wire Electrical Discharge Machining, commonly known as Wire EDM, is a highly specialised manufacturing process that uses electrical sparks to cut and shape electrically conductive metals with incredible precision. This technique is particularly valuable when machining tough or exotic materials that are otherwise difficult to process, such as Inconel, hardened tool steels, tungsten carbide, titanium, aluminium, and copper alloys.
Wire EDM utilises a thin, electrically charged wire, usually made of brass or copper, as a tool electrode. Unlike traditional machining, the wire does not physically touch the workpiece; instead, a series of controlled electrical discharges occur between the wire and the metal, eroding the material along the desired cutting path. The wire is continually fed through the machine, ensuring it does not degrade or erode itself during the process, which maintains accuracy and surface finish.
This process is ideal for cutting intricate, complex shapes that require high levels of accuracy and fine surface finishes. Because the material is eroded by sparks rather than mechanical force, Wire EDM can create parts with sharp internal corners and thin sections that would be impossible or costly to achieve using traditional methods.
How does the Wire EDM process work?
The Wire EDM process begins by programming the desired shape into a CNC controller. The machine then guides the wire electrode along the programmed path, generating sparks that vaporise microscopic amounts of metal with each pass. For parts where surface finish and dimensional accuracy are critical, multiple skims or fine passes remove microns of material to achieve the required finish and tolerances.
Wire EDM is favoured by industries demanding intricate detail and reliability. For instance, the defence sector relies on precision parts for weapons and systems, while medical and pharmaceutical companies use it for surgical instruments and implantable devices. Similarly, aerospace, motorsport, and space industries require components with the utmost accuracy and surface integrity.
Our State-of-the-Art Machinery
At Microtec EDM, we operate GF CUT 1000 machines, cutting-edge technology in microwire erosion. These machines use wires as thin as 20 microns and can achieve surface finishes down to Ra 0.05 microns. With the ability to create inside radii as small as 11 microns and slits of 22 microns, our Wire EDM machinery is capable of producing the finest components required by sectors such as watchmaking, automotive, aerospace, and satellite technology.
The combination of small and high-volume batch production capabilities means we can support both prototype and large-scale manufacturing needs, maintaining consistent quality every step of the way.
The Importance of Inspection & Quality Control in Wire EDM
In the world of precision engineering, where microns matter and reliability is non-negotiable, inspection and quality control are not optional; they are essential. This is particularly true in Wire Electrical Discharge Machining (Wire EDM), where even the smallest error can have significant implications. At Microtec EDM, we know that producing high-performance components doesn’t stop at machining excellence; it requires a rigorous, methodical approach to quality assurance at every stage of production. That’s why robust inspection and quality control processes are fundamental to successful outcomes. Here’s why quality control is essential in Wire EDM…
Dimensional Accuracy Checks
Precision is everything in Wire EDM. Parts often have tolerance limits within microns. Coordinate Measuring Machines (CMMs), like the Hexagon Global S Probe and our upgraded Nikon Optical CMM, allow us to measure complex geometries with pinpoint accuracy, ensuring every dimension conforms to your exact specifications.
Surface Finish Validation
Many components—especially those in the medical, watchmaking or aerospace sectors—require not only accuracy but a flawless finish. We use surface testers and microscopes to confirm that the Ra (roughness average) values meet required standards, ensuring not only function but also aesthetic integrity.
In-Process Inspection
Rather than leaving quality checks to the end, our approach integrates inspection throughout production. At every key stage, components are assessed for dimensional conformity, alignment, and material consistency. This allows us to catch and correct anomalies early, reducing waste and ensuring a smooth production flow.
Material Integrity Verification
Especially in industries where safety and performance are critical, it’s vital to ensure that the material properties remain intact after machining. We conduct hardness testing to confirm that the Wire EDM process hasn’t altered the component’s structural integrity, maintaining strength and durability.
Gauge and Instrument Calibration
All of our inspection tools—from handheld devices to sophisticated digital instruments—are regularly calibrated in line with our ISO 9001:2015 obligations. This guarantees consistent and reliable measurements, with traceability and full documentation available upon request.
Environmental Control for Accuracy
Our purpose-built inspection room is fully air-conditioned to minimise thermal expansion and contraction of materials during measurement. This ensures consistency and reliability in our readings, especially when working with extremely tight tolerances.
Visual and Optical Inspection
High-resolution optical projectors and borescopes allow our technicians to inspect internal features, tiny slits, and complex cavities that cannot be evaluated with traditional methods. This is particularly useful for components with intricate features or hidden geometries.
Full Inspection Documentation & Reports
Clients often require full traceability and verification for every part delivered. We provide comprehensive inspection reports—including First Article Inspection Reports (FAIRs), Certificates of Conformity (CoCs), and measurement data—on request, offering complete transparency and peace of mind.
ISO 9001:2015 Accredited Processes
Our commitment to quality is embedded in everything we do. Microtec EDM operates under the ISO 9001:2015 quality management system, ensuring that all processes, documentation, and inspections follow globally recognised standards.
Tailored Quality Control Solutions
Every project is unique. We work closely with clients from the outset to define the level of inspection required—whether that’s sample-based validation or 100% inspection with detailed reports. This flexibility ensures we meet regulatory, functional, and commercial requirements without adding unnecessary cost.
Inspection and quality control in Wire EDM are not just about box-ticking—they are vital, value-adding aspects of the manufacturing process. At Microtec EDM, we take this responsibility seriously. With a dedicated inspection facility, a skilled and accredited team, and a suite of state-of-the-art equipment, we deliver not only precision parts but complete confidence in their performance.
When you partner with Microtec, you’re choosing more than just machining expertise, you’re choosing a company that stands by its quality, every step of the way. Contact us today!
Our Dedicated Inspection Facility
Microtec EDM boasts an in-house, fully equipped inspection facility designed to support our precision machining services. We employ advanced inspection tools, including multi-axis coordinate measuring machines (CMMs), optical projection systems, hardness testers, and gauge calibration devices. This comprehensive toolkit enables us to detect even the smallest discrepancies and ensure the highest level of product integrity.
Since relocating to our Shoeburyness site in 2017, we have enhanced our inspection capabilities by introducing the Hexagon Global S Probe CMM, complementing our Nikon Optical CMM, which was recently upgraded. Our climate-controlled inspection room is also fitted with borescopes, microscopes, and surface testers—all calibrated under the rigorous ISO 9001:2015 quality system standards we uphold.
What can we do for you?
At Microtec EDM, inspection is integrated seamlessly into our production workflow. From the very first stage to final delivery, we perform in-process inspections and validations to detect and correct issues immediately. This approach reduces scrap, improves yields, and maintains tight tolerances without added cost to the client.
We also offer bespoke inspection plans based on your specific requirements. Whether you need a full 100% inspection with comprehensive documentation or targeted quality checks, we can tailor our services accordingly. If you’re unsure about your inspection needs, our experienced team is on hand to provide guidance and recommend the most suitable solutions.
Fully Accredited & Approved Team
Our skilled and highly qualified team provides a complete production service, from initial CAD design assistance and prototyping to mass production with full product traceability. We hold ISO 9001:2015 accreditation, reinforcing our commitment to maintaining the highest standards of quality management throughout every phase of manufacturing.
How can Microtec help?
Microtec EDM is more than just a Wire EDM service provider, we are your partner in precision manufacturing. Here’s how we can add value to your projects:
- Expertise Across Industries: With over two decades of experience, we understand the unique challenges of industries ranging from aerospace to medical devices.
- State-of-the-Art Technology: Our latest GF CUT 1000 Wire EDM machines and advanced inspection equipment enable us to deliver parts with micron-level accuracy.
- Comprehensive Quality Assurance: From initial design to final inspection, we maintain tight controls to guarantee the quality of every component.
- Customised Solutions: We offer tailored services including prototype runs, small batches, or large production volumes to fit your needs.
- Full Traceability: We maintain rigorous documentation and product traceability for total peace of mind.
- Responsive Customer Support: Our friendly team is always ready to discuss your project requirements and offer professional advice.
Ready to get started? Contact us today for more information about our services!
Precision That Inspires Confidence: Why Quality Control in Wire EDM Matters
In conclusion, the fusion of advanced Wire EDM technology with comprehensive inspection and quality control processes forms the foundation of reliable, high-precision manufacturing. At Microtec EDM, we combine cutting-edge machinery with an unwavering commitment to quality to ensure that your components perform flawlessly in the most demanding applications.
If you’re seeking a trusted partner to deliver precision parts backed by thorough inspection and quality assurance, Microtec EDM is here to help. Contact us today to discuss how we can support your manufacturing goals with excellence and integrity.
FAQs
What materials can be cut using Wire EDM?
Wire EDM can cut any electrically conductive material, including Inconel, hardened tool steels, tungsten carbide, titanium, aluminium, and copper alloys.
How accurate is Wire EDM machining?
Wire EDM machines can achieve dimensional tolerances in the micron range and surface finishes as fine as Ra 0.05 microns.
What industries benefit most from Wire EDM?
Aerospace, medical, pharmaceutical, defence, automotive, motorsport, watchmaking, and satellite technology industries frequently utilise Wire EDM.
Why is inspection important in Wire EDM?
Inspection ensures parts meet exact specifications, prevents costly errors, and maintains consistent quality across production batches.
What inspection equipment does Microtec EDM use?
We use multi-axis CMMs, optical projection, hardness testing, borescopes, microscopes, and surface testers in a fully calibrated environment.
Can Microtec EDM handle both prototypes and mass production?
Yes, we have the flexibility to manage both small prototype runs and high-volume production.
What is the role of ISO 9001:2015 accreditation?
It demonstrates our commitment to maintaining a rigorous quality management system throughout our operations.
Is in-process inspection available at Microtec EDM?
Absolutely. We perform in-process inspections to validate quality throughout manufacturing.
How thin can the wire used in Wire EDM be?
Our machines can use wires as thin as 20 microns to achieve detailed, precise cuts.
How do I know what inspection services I need?
Our experienced team will help assess your requirements and recommend a tailored inspection plan.
Ready to Experience Unmatched Precision?
For expert Wire EDM services backed by world-class inspection and quality control, trust Microtec EDM. Contact us today to discuss your project requirements and discover how our precision manufacturing solutions can elevate your business.