Wire electrode discharge machining (EDM) is the most cost-effective way to shape small, complex parts from titanium, says DEW Technologies President Ron Jobe. He says the machines require less tooling and maintenance as compared to many conventional machines. Jobe adds that EDM machines also work well on aluminum and high-alloy and stainless steels. The Fairborn, Ohio-based company (DEWTEC.com) uses Mitsubishi wire EDMs (www.mitsubishi-world.com) to make tight-tolerance components for spinal and fracture-fixation medical implants. The machines handle both small prototype quantities, as well as large, multi-fixtured production runs.

DEW also uses a sinker EDM in conjunction with a 3R Workmaster Robot in a production cell. The sinker's electrode is used to “ram“ into a part to form hard-to-reach or difficult-to-machine geometries. “The wire and ram EDM equipment allow for flexibility in processing to meet the dynamic needs of the medical-device market,” says Jobe.