While laser cutting and wire EDM cutting are both fine choices for your precision cutting needs, there are some differences between the two. Depending on the type of material you are cutting, and the end use one process may be preferable to the other.

So, what are the differences between laser cutting and wire EDM cutting?

In short, each process performs best with different products and different applications. Laser cutting is for the hardest of materials(Such as PCD, PKD, CVD, Mono crystall diamond, Ceramic, Tungsten Carbide etc.) while wire EDM has the capability of cutting thicker materials. Wire EDM can also work with tighter tolerances than laser cutting.

We will get into more detail on these differences below, beginning with how the two operations actually work.

The Process

The first distinction between laser cutting and wire EDM cutting is the process in which they operate. Laser cutting is a precision technique that uses a beam of light to burn and/or melt a path through the material being cut.

Essentially, a machine agitates electrons to a point in which they give off light in the form of photons. These photons then reflect back and forth repeatedly and form a laser that is very high in power. The laser makes contact with the material being cut, and this contact point heats to such a degree that the material melts.

Once the laser has melted its way through the entirety of the piece of material through this contact point, it can then begin moving and cutting where necessary.

Wire EDM cutting, on the other hand, uses an electrically charged wire to machine and cut through material. EDM stands for electrical discharge machining. During the wire EDM process, the wire does not actually come into contact with the material being cut. Instead, the wire is electrically charged to a high enough voltage that a spark is created that leaps from the wire to the material, melting a path through it.

This process is conducted in dielectric water so that any dust or contaminants created are quickly swept away so as to not affect tolerance.

Material

As laser cutting begins with a contact point, and that contact point must first pierce through the entirety of the piece of material, laser cutting works best with lighter, thinner objects. It also requires non-reflective material.

Since the wire EDM process does require electricity, the material must be conductive, meaning that it must be a metal or an alloy. This process is capable of cutting very thick metals, up to 12 inches and sometimes thicker.

Tight Tolerances

Another difference between these two processes is the tolerance that each can machine to. Laser cutting has the ability of machining tolerances up to .001 inches and sometimes .05 millimeters depending on how thin the material is.

Wire EDM cutting, on the other hand, is extremely precise, capable of machining to .0001 inches. This also means that the wire EDM process is slower than laser cutting. For product with extreme tight tolerances or that require immaculate precision, wire EDM may be the best option.

Summary

Laser Cutting:

Uses a beam of light photons to melt material for cutting

Perfect for thinner, lighter material that is non-reflective

Can machine to a tolerance of around .001 inches

Moves faster than wire EDM cutting

Wire EDM Cutting:

Uses an electrically charged wire and conductive material to create sparks that melt the material for precision cutting

Perfect for thicker and heavier machining with conductive materials

Extremely precise machining to a tolerance of .0001 inches or more

Moves slower than laser cutting

Both laser cutting and wire EDM cutting have their time and place when it comes to manufacturing. It is important to do the research and understand which technique will optimize your workflow and give the quality you need.

TKD laser can help recommend the best process that suits your manufacturing needs. With over 10 years of comprehensive PCD, PKD and other cutting service experience, we have one of the largest laser cutting capacities for superhard materials in China, and provide beneficial PCD, PKD, CVD, Ceramic Tungsten Carbide cutting solutions for industries such as defense, automotive, and industrial sectors. If you need laser cutting services and laser cutting machines, please contact TKD immediately for a free estimate!