For microEDM, the most important applications are: small precision cutting punches and dies, precision moulds, components for medical engineering, sensors and optics, watch making (gears and holes) or the production of small multi-component electrodes.

The first applications of micro electro discharge machining were implemented in the 90s, when thin electrodes were used to develop micromechanic systems and microfluidic components for non-invasive medics, micromechanisms for pharmaceutics and micro-chemistry [13]. The process was slow by then, reason for which the application was limited to universities and research centres.

At present, micro EDM is a key technology for the production of microtooling for microinjection and micropunching  because it can machine hard alloys and tempered steels that can withstand the wear produced by the processed materials.

Some important players in the application of micro EDM are:

Maroney Company [14] in Northridge, California, (http://www.maroneycompany.com) uses Agie Evolution machines and dedicates a 10% of its production to thin wire EDM. The company puts a special stress in the planning of thin WEDM operations to reduce the machine preparation costs. It is the only provider of some special components for the Space and Defence USA Ministry and for NASA (propulsion system of the Pathfinder in Mars). They have manufactured the World smallest mass spectrometer. The company is specialised in the machining of series of 2~3 components, being ~100 parts the maximum order. Some fields of application of the produced components are: remote sensing systems, arterial catheters, insulin dosing systems, etc.

Speciaty Tool & Engineering [15] in Minneapolis,( http://www.specialtytool-eng.com) Minessota, develops systems foro the hard drive industry (hard metal guides to introduce the cables inthe hard drive), medical instrumentation (endoscopies), etc. They use Fanuc WEDM machines with wires down to Ø0.05 mm.

Miniature Tool and Die (MTD) (http://www.miniaturetool.com) manufactures tooling as small as 1.5 mm long with 38 mm walls by combining micromilling, microEDM and lithographic techniques.

Figure 13 – Microsensor with 0.051 mm slots (left). Extrusion matrix with 25 mm slots (right)

Helmut Christmann GmbH (http://christmann-gmbh.de/fx) is a German company located in Birkenfeld with an important background in the application of thin WEDM [16]. Among other areas of expertise, the company is specialised in the production of precision moulds, punches and dies, as well as precision mechanical systems.

The company uses AGIE and Sodick machines working with wires down to Ø0.03 mm. It is considered as one of the key providers of EDM services in Europe.

Figure 14 –Helmut Christmann GMBH Facilities.

Figure 15 – Some examples of componenst machined by thin-WEDM

The German company Profiform GMBH produces punches and precision moulds for the injection of plastic components. It uses Agie machines (11 machines, one Agiecut Vertex and one Agiecut Excellence 2F). The sectors for which the company Works are: electronics (light measurement and optical engineering), automotive, medics and aerospace.

Figure 16 – Components machined by Profiform GmbH

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