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No matter for injection mold, pressure die casting mold, compression mold, EDM sparking is one of the essential manufacturing processes.
EDM sparking is for machining the areas where CNC machining cannot reach. For example, small ribs, radius corners, deep concaved bottom and etc. Its principal is that with high electricity releasing from a electrode, then melting the steel off with a shape designed.
Comparing with CNC machining, wire cutting, EDM sparking would be more expensive comparing with the other essential processes. It’s because that CNC machining and wire cutting is a direct process. While EDM sparking is an indirect process. Before sparking, we would have to CNC copper electrodes or carbon electrode in advance.
In the video, 2 are from automatic EDM sparking machine. One is from a traditional manual EDM sparking machine. Automatic EDM sparking machine is the trends, as it’s more efficiency and with high accuracy, even though the machines are more expensive. Side-sparking is a common available function by automatic EDM sparking machine, but no by traditional sparking machines. Some high-tech EDM sparking machines even can provide rotation sparking. For example, for the tread features.
For rapid tooling and low volume production, we often suggest our customer to design the parts as less as possible with EDM sparking, but with CNC machining as much as possible. For example, larger internal radius, less ribs if without effecting part strength, bigger ribs can be machined if possible, shallower concaved features and etc. They can help saving the tooling cost a lot and speed up the tool making. Anyway, most of the time, we would have the part function limitation and can not too much adjustment for manufacturing.
By the way, sometimes the sparking areas will be left just as what it’s sparked. It’s similar to textured surfaces and can be for cosmetic.
More injection molding or quick-turn manufacturing information, please visit our manufacturing resources center at www.dankemold.com/resources