In the world of modern manufacturing, where tolerances are tight and materials are tough, traditional machining methods often fall short. That’s where EDM spark erosion comes in—a cutting-edge process that’s reshaping how complex parts are made.

Whether you're in aerospace, medical, toolmaking, or precision engineering, spark erosion offers unmatched precision, reliability, and versatility. At Erodex, we’ve been at the forefront of supplying top-quality EDM consumables and materials for over four decades. Here's everything you need to know.

What is EDM Spark Erosion?

EDM (Electrical Discharge Machining) Spark Erosion is a non-contact machining process that removes metal using controlled electrical discharges—or sparks—between an electrode and the workpiece. The process occurs in a dielectric fluid and only works on electrically conductive materials, such as steel, carbide, titanium, or exotic alloys.

Instead of using mechanical force to cut, EDM spark erosion uses heat generated from electrical energy to vaporise material with extreme precision. This makes it ideal for manufacturing intricate shapes, fine details, and hard-to-reach internal cavities.

How Does It Work?

1. Electrode Selection
   An electrode, usually made of graphite or copper, is shaped to mirror the desired geometry.
   
   
2. Controlled Spark Generation
   A high-frequency power supply creates sparks between the electrode and the workpiece.
   
   
3. Material Removal
   Each spark generates intense heat—up to 12,000°C—that melts and vaporises tiny amounts of material.
   
   
4. Dielectric Flushing
   Dielectric fluid cools the process, removes debris, and controls spark formation.

This cycle repeats thousands of times per second, eroding the workpiece with extraordinary precision.

Benefits of EDM Spark Erosion

• No Physical Contact – Eliminates mechanical stress and tool pressure.
  
  
• Machine Hard Materials – Perfect for tungsten carbide, Inconel, and hardened steels.
  
  
• Micron-Level Precision – Achieve tolerances as tight as ±0.005mm.
  
  
• Intricate Geometry – Create fine holes, complex contours, and internal features.
  
  
• Superior Surface Finish – Controlled sparking reduces post-processing.
  
  

EDM Spark Erosion Applications

At Erodex, we see EDM spark erosion used across numerous sectors:

• Aerospace: Turbine blades, injector nozzles, and engine components.
  
  
• Medical: Surgical tools and implants with complex contours.
  
  
• Automotive: Fuel system parts, mould tools, and gear profiles.
  
  
• Tool & Die: Die sinking, cavity cutting, and mould making.
  
  
• Electronics: Micro components with delicate features.

Erodex: Your Trusted EDM Supply Partner

We provide everything you need to run a successful spark erosion process:

• High-Purity Graphite Electrodes – Custom-machined to your specifications.
  
  
• Copper & Hybrid Electrodes – For fine finishing and deep cavities.
  
  
• EDM Tubing and Fast Hole Drilling Tools – Precision tubing for high-speed operations.
  
  
• Dielectric Fluids & Filters – Keep your spark erosion systems clean and consistent.
  
  
• Consumables & Accessories – Including holders, collets, guides, and wire.

Our in-house experts understand the challenges of spark erosion and work closely with manufacturers to recommend the best solutions based on material, application, and machine type.

Why Choose Erodex?

1. 40+ years of EDM experience
   
   
2. UK-based manufacturing and global supply network
   
   
3. Fast delivery and dedicated technical support
   
   
4. Custom machining services for electrodes and tooling
   
   
5. Trusted by aerospace primes, defence contractors, and medical OEMs

Ready to Optimise Your Spark Erosion Process?

Contact Erodex today for industry-leading EDM spark erosion materials and support.

Based in the West Midlands, UK
Call us at +44 138 489 2011
Visit www.erodex.com