Last time we talked about what goes into a perfect design. This time we look at some common everyday objects that could use a bit of redesign. All of the following have served their purposes admirably over the years, answering a felt need and in the process becoming ubiquitous in the modern world. But with advances in manufacturing technology and design capabilities we think they might stand for a bit of improvement, if there’s a clever designer or two out there who’s up to the challenge.

Rain falls on everyone. It’s a fact of life, and if it’s not rain then it’s too much sun. How to stay dry and in the comforting shade has been a common human concern for thousands of years, and so too the umbrella has been with us in one form or another since at least the time of the ancient Egyptian and Persian empires. Having gone through a series of technical and design innovations over the centuries, the modern version of the umbrella is familiar around the world: a central shaft around which is mounted a series of struts over which is strung a fabric cloth that, when deployed, sheds water and blocks the rays of the sun. Ideal, yes, and even somewhat elegant and sophisticated at times.

And yet who among us hasn’t struggled with the umbrella in a heavy wind, the parasol turning inside out and pulling us along the wet street like a drag chute? The struts break, water cascades down our backs or into the tops of our shoes. Umbrellas get tangled in doorways, drip water into the house, flap about like broken birds. If you’re on a crowded street during a shower, getting poked in the eye by the person next to you is a very real concern. And is there any sight sadder than this?

How many city streets are littered with umbrellas that have given up their last gasp? If there’s a better metaphor for the disposability of modern life, we don’t know it.

The design brief calls for a transparent, durable plastic shell for displaying a product on a store shelf, often some new electronic device. When the consumer buys the product, they take it home and then they are faced with the dreaded blister pack or clamshell that must be clawed through to get to the contents. And then the swearing starts, and then out comes a pair of scissors, knife, hacksaw or axe to get through the pack without destroying the thing you just bought. There’s actually a name for this phenomenon called “wrap rage”, and nothing has inspired it more than the blister pack and the sharp, pliable edges that tear into fingers and make a mockery of your shopping day. Some have attempted to solve this dilemma with innovative solutions such as this:

Is this the answer we’ve all been waiting for? Only time, and the fickle consumer, will tell.

While we’re on the subject of packaging – itself a lengthy topic – here’s one that may soon be disappearing from our lives, much to our general relief. The compact disc, or CD, started coming out into mass production in the early 80s, when digital music formats were beginning to sound the death knell to the beloved old vinyl LPs and stereo cassettes. CDs were indeed compact and promised us they would be durable, foolproof and keep providing pleasure year after year. Not so with the jewel case in which they were packaged. Although pristine when first opened, every jewel case cover ever made would soon snap off at the flimsy hinges.

The album cover art, printed onto cheap paper, would be wedged under four little plastic tabs. And then it would inevitably fall out, and putting it back was an exercise in monastic patience. And that little spindle in the center of the case, meant to hold the CD securely in place? The fingers snapped off, leaving the CD jostling around and getting scratched up, exactly what it was supposed to prevent. The jury is still out concerning what sounds best: vinyl LPs, CDs, or now lossless digital music files. But whatever history’s verdict, the jewel case was a design that never should have been.

Commercially successful typewriters were invented in 1868, and like umbrellas they’ve gone through many iterations over the years. By now, we’re all familiar with the so-called “qwerty” keyboard.

Legend has it, probably apocryphal, that the letters of the top row were arranged that way by an early and enterprising door-to-door salesman, who wanted to demonstrate how to spell the word “typewriter” on a single line. It’s more likely that the peculiar arrangement is due to the typewriter’s early use as a transcribing device for telegraph messages that were sent in code. Whatever the initial reason, looking at the keyboard objectively doesn’t reveal any good reason for why we continue to use it in this form today. It’s not the most ergonomically efficient array at all, and other competing designs, such as the Dvorak keyboard, have been attempted but all have failed to gain the public’s acceptance. So taken are we with this as the standard that we reproduce it on the touch screens of smart phones, which have no keys at all. This is simply a case where familiarity trumps function, and there’s no use fighting it.

There are other candidates on this short list. Possibly “hands-free” water faucets, which never seem to register the presence of a soapy, dirty hand desperately in need of washing. Who hasn’t waved their hands about underneath such a spigot, yearning for a proper handle? Maybe electrical multi-outlet strips, where one large plug always seems to block the space next to it, rendering the entire exercise moot. Other examples abound, and everyone has their favorite. These are important things to consider when designing your next prototype project. A design is never really finished. It can always be improved upon, simplified, streamlined. Another advantage to rapid prototyping and the flexibility it gives you to hone a product until it approaches the perfection of a mousetrap. Let us know what you think are the best and worst designed products out there.

There are many rewarding aspects of producing industry-leading CNC routers and CNC plasmas, but none more rewarding than hearing success stories from ShopSabre customers around the country.

Among these great success stories is Olies Wood Shop in Los Angeles, who added a ShopSabre CNC router to their arsenal a few years back to ramp up their production and efficiency.

From hand-crafted beginnings

Olies Wood Shop is a furniture and dcor shop owned by the husband-and-wife duo of Art and Olie. Arts father moved to the U.S. from Honduras and started his own woodworking company decades ago, eventually helping Art start his own shop years later. At first, Art and his dad produced every part for every project by hand, which resulted in slow project timelines when creating furniture.

Because of this, they knew they needed a change once the business began to grow. They needed to find a way to be more efficient, and eventually started researching CNC machines.

Eventually, Art found ShopSabre, and began communicating with the team on possible equipment options.

For me it was a big investment, purchasing a CNC machine. After exchanging emails, I knew that ShopSabre was the company that I wanted to go with because the machines were very well-built and the price was very very reasonable for what you get.

Art also made note of the ShopSabre teams responsiveness in answering his many questions about CNC and the purchasing process.

Olie comes around

Despite Arts glowing first impression, Olie was not yet convinced. The couple spent a lot of time discussing the purchase and she came to understand how much a CNC router from ShopSabre would help the shops production. Art showed her the website and the benefits of CNC and just how much it would streamline many aspects of the business.

Eventually, Olie agreed, and now says purchasing a CNC router with ShopSabre was the best decision the shop has ever made.

This helps us produce so much more, Olie said. The machine is like five employees in one.

CNC changes the game

As Olies has grown, more and more orders have begun coming in orders theyd previously have been unable to fulfill without the help of CNC technology. Art and Olie are now able to cut an entire desk that would have previously taken five hours in just 15 minutes.

Because the machine automates so much of the production process, it also allows them to perform additional work around the shop and opens up new opportunities to create one-of-a-kind furniture while maximizing profitability.

The CNC software took a bit of education, which the ShopSabre team was able to assist in at every turn.

Obviously theres a learning curve, so its nice having that customer service anytime we needed help. Theyre very patient with us.

Even Arts dad whos been a woodworker for 40-plus years finds himself taking advantage of the CNC router in order to save time.

What would have taken him five hours takes the machine five minutes. We program it and everything, draw it up, and its done.

Art and Olies advice for first-time CNC buyers

From Arts experience in purchasing a CNC machine, his advice for first-time buyers is to opt for more options and functionality if you can afford it, as doing so is less expensive when paired with your initial purchase.

He and Olie also note that while CNC software can be intimidating to first-timers, it is much easier to work with than expected and is also supported by a wide range of tutorials and educational resources including ShopSabre customer service.

If we havent asked the question, someone else has. They know their stuff like the back of their hand. Theyll be on the phone and work with you. Theyre amazing at customer service.

The future of Olies

The addition of CNC technology to Olies shop has opened up new doors for them, especially in beginning to experiment with aluminum and other metals. Art and Olie are not metalworkers by trade, so ShopSabre has helped them learn the process in terms of setting feed speeds, working with different types of bits, and more.

Now theyre considering adding a ShopSabre CNC plasma to the shop to even further expand on their capability.

There are so many ideas we have for Olies as far as designs and different types of furniture that we want to build, and incorporating aluminum and steel, and its all possible because of the ShopSabre CNC machine.

Transform your shops capabilities with ShopSabre CNC

ShopSabre manufactures world-leading CNC routers and CNC plasmas to provide hobbyists and shop owners alike with unmatched precision, efficiency, and versatility. Whatever your goals may be, we are dedicated to helping you produce outstanding results at a fraction of the labor and cost.

OurIndustrial Series (IS)andPRO SeriesCNC routers provide industrial capability for a fraction of the price, while ourSideKick CNC plasmasdeliver professional quality at an entry-level cost.

Here are a few of the reasons ShopSabre is able to develop and produce such revolutionary CNC technology:

• Experienced in-house engineering talent
• The ability to totally fabricate and test designs onsite
• The ability to place the designs into production in-house

These are just a few of the advantages of being an American machine tool manufacturer. We offer commercial financing on our CNC equipment to help meet the needs of your budget.

Shop our unmatched collection of CNC routers and CNC plasmas in Minneapolis today to experience CNC the way it was meant to be.

Wire EDM machining is an electrothermal production process that uses electric discharges to remove material from a workpiece. It is an improvement to the conventional EDM method, compatible with almost all conductive materials, and can create complex designs and shapes.

As a result, many parts manufacturers across several industries use it, as it is highly recommended in many CNC machine shops. This article will discuss wire EDM cutting, compatible materials, and its application in many industries.

Contents
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I
What is Wire EDM?

II
How Does Wire EDM Work?

III
Components of A Wire EDM Machine

IV
Materials A Wire EDM Machine Can Cut

V
Differences Between EDM Wire Cutting and Conventional EDM

VI
Pros and Cons of Wire EDM Machining

VII
Applications of Wire Electrical Discharge Machining

VIII
Conclusion

IX
FAQ

What is Wire EDM?

Wire electrical discharge machining is a non-contact subtractive manufacturing process that uses an electrically charged thin wire with a dielectric fluid to cut a metal part into different shapes.

The process produces small chips and precise cut lines by melting or vaporizing the material rather than cutting it. As a result, it can conveniently machine parts unsuitable for conventional machining techniques. However, the parts must be electrically conductive.

How Does Wire EDM Work?

The wire-cut EDM process has a simple mechanism.

Machining a part using the process involves submerging the workpiece into a dielectric fluid, securing it with a machinist vise, and running the wire through it to produce sparks as it passes an electric current.

In other words, the wire carries one side of the charge, and the workpiece, which must be a conductive material, carries the other side of the charge. When the two get close, a hot electric charge jumps the gap and melts tiny pieces of the metal away.

The electric spark is the cutting tool to cut the material in the desired shape. Additionally, the wire EDM process involves deionized water to control the process and flush away tiny particles removed.

Components of A Wire EDM Machine

The machine comprises several parts that work together to give a material the desired shape. Below are the components of the machine.

1. CNC Tools

The CNC tools control the entire operation of the Wire EDM machining process. Controlling the entire operations include being in control of the sequencing of the wire path and being able to manage the cutting process automatically.

Note: The CNC tool’s sophistication determines the error level and the machining time.

2. Power Supply

The power supply unit is the component that delivers pulses (from 100V to 300V) to the wire electrode and the workpiece. Furthermore, it controls the frequency and strength of the electrical charges that pass through the wire electrode to interact with the workpiece.

It is necessary to use a highly developed power supply unit to deliver the necessary quality and type of charges during Wire EDM machining.

3. Wire

The wire serves as the electrode to create the electrical discharge. The shape and thickness of the workpiece directly influence the wire’s diameter. Typically, one can use wires with diameters ranging from 0.05 to 0.25mm. The main types of wires used include

-Brass Wires

Brass is the most common EDM wire material because of its excellent conductive properties. It is an alloy of copper and zinc, and the higher the zinc content, the faster the wire cuts. However, there should be a balance because when the zinc content is over 40%, this decreases the corrosion rate of the brass wire.

-Zinc coated Wires

As the name implies, you obtain it by applying a coating of pure zinc or zinc oxide on the wire surface. Manufacturers use zinc-coated wires because it improves the machining speed.

-Diffusion-annealed Wires

The diffusion annealing process helps to create wires with higher zinc content (more than 40% zinc). It involves coating wires with layers of pure zinc. These wires are ideal for mass production and can machine many materials.

-How to Choose the Right Wire

• To choose the right EDM wire material for your project, consider the following
• Tensile Strength
• Fracture Resistance
• Conductivity
• Vaporization Temperature
• Hardness

4. Dielectric Medium

The wire-cut EDM process must be carried out in a tank filled with dielectric fluid. This liquid prevents the tiny particles from the workpiece from getting attached to the wire electrode. The most common medium is deionized water which cools the process and gives the workpiece a good surface finish.

5. Electrodes

The electrodes in the machine are the wire (cathode) and the workpiece (anode). The servo motor controls the wire electrode, ensuring it does not come in contact with the workpiece at any point during the wire EDM cutting process.

Materials A Wire EDM Machine Can Cut

Wire EDM machines can create complicated shapes and patterns on a workpiece. Additionally, they can machine most materials that can conduct electricity, even the tough and delicate.

Common shapes and materials you can cut with the machine include:

Aluminum

Aluminum has excellent thermal and electrical conductivity properties. However, aluminum is naturally soft and can be challenging to cut with the process as it may result in a gummy build-up after machining.

Titanium

Wire EDM cutting is perfect for titanium because the process can withstand the stickiness of this alloy and break up lengthy chips. However, you need deionized water as the dielectric medium to help control heat generation during machining.

Steel

Steel is a very strong metal. As a result, many manufacturers favor using a wire EDM machine over a CNC machine. However, the material generates a lot of heat, so one needs to take the necessary precautions.

Brass

Brass is easy to cut using the machine because it has high tensile strength. However, the cutting speed should be slow because it is a soft metal.

Graphite

It may be difficult to cut graphite using conventional cutting tools. But the wire EDM process is appropriate because the wire is sharp, preventing particle pull-out.

Differences Between EDM Wire Cutting and Conventional EDM

The wire-cut EDM process is an improvement on conventional EDM. Their mode of operation is similar. However, they have significant differences. Below is a few difference between both machining process.

Electrode

As stated above, the electrode used in wire EDM cutting is a thin heated wire. In contrast, conventional EDM uses highly conductive metals like graphite or copper electrodes to produce electrical charges. The electrodes are in different shapes and sizes, which affects their smoothness. For example, a round electrode produces the smoothest surface. Then a square, triangle, and diamond. When the electrode is inserted into the workpiece, it forms a mold leaving a ‘negative’ impression of its shape.

Speed of Machining

The electrodes of conventional EDM must come in different shapes. As a result, manufacturers must create and shape them before the machining process, and this takes time. In contrast, the wire EDM machine is ready to use as soon as the wire is in position. This makes it appropriate for applications that must need to be completed quickly.

Accuracy

Wire EDM machining makes use of wire as the electrode. As a result, they have better accuracy than conventional EDM. For example, the wire electrode allows them to cut at a thickness of about 0.004inches. Due to their accuracy, they become better suited for machining parts with complex shapes and designs, unlike the conventional EDM, which is more suitable for more rigid cuts.

Applications

Wire EDM machining is versatile and can cut ferrous and non-ferrous metals, so many industries use it. Also, size and shape do not limit its use because it can machine both long parts and extremely small ones. However, conventional EDM can handle harder and thicker materials because the thickness of the wire electrode in a wire EDM machine affects its use.

Pros and Cons of Wire EDM Machining

Pros of Wire EDM

• It makes precise and accurate cuts eliminating the need for further processing and finishing of the workpiece.
• The process is suitable for creating complex designs and shapes that are otherwise challenging to produce using traditional CNC machining.
• It is applicable in machining small parts and for cutting highly detailed items that would otherwise be too delicate for other machining options.
• Wire EDM machining is ideal for fragile materials and cannot withstand the stress of machining.
• With just one stage of processing, the machine cuts materials leaving no burrs or distortion.
• The machining process cuts continuously without interruptions. Even if the wire breaks when cutting, the process continues immediately.

Cons of Wire EDM

• It is only compatible with materials that conduct electricity.
• An oxide layer may develop on the cut surface of some materials, such as aluminum. Therefore, this could necessitate additional finishing, which raises the cost.
• It has a high initial investment and maintenance cost.

Applications of Wire Electrical Discharge Machining

Many industries use wire EDM machines from prototyping to complete production runs. Below are some industries.

Automotive Industry

The parts in the automotive industry come in complex shapes and sizes and are mostly hard. As a result, the industry favors using wire EDM machines because the process does not rely on mechanical forces, and the wire electrode does not need to be stronger than the workpiece. The process applies to making holes and cavities to customize automotive car parts like bumpers, dashboards, car doors, and many more.

Medical Industry

Wire EDM machines produce complex parts with a high level of accuracy for use in all medical fields, including optometry and dentistry. Also, metals that work well with wire EDM services are frequently used to manufacture medical equipment.

Since the wire’s diameter determines the cut’s size, the wire EDM machine adds tiny features to parts like dental implants and syringe components without endangering their structural integrity.

Aerospace Industry

Wire EDM cutting produces parts with tight tolerances and is the go-to machining process for aerospace part manufacturers. This process, alongside the waterjet cutting process, is especially used for parts that cannot withstand the high temperature and stress associated with traditional cutting tools.

Parts in the aerospace industry need to have an excellent surface finish and be precise and accurate. Manufacturers use the wire EDM process for years to make engines, turbine blades, landing gear parts, and many more.

Conclusion

Wire EDM is a versatile and precise machining process that can be used to create complex shapes and geometries. It is often used in the aerospace and medical industries, where parts need to meet tight tolerances. Wire EDM can also be used to create prototypes or one-off parts. In this article, we hope that you now have a better understanding of wire EDM.

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Simply upload your CAD file today to receive an instant quote. We’re happy to work with you to find the right solution.

FAQ

What are the other types of EDM available?

Other than wire EDM, there is the hole drilling EDM and sinker EDM. The difference is in the electrode used. The electrodes in hole EDM are tubular and create tinier and deeper holes. On the other hand, sinker EDM uses an electrically conductive metal to form a ‘positive’ of the desired shape.

What’s the difference between wire EDM and laser cutting?

Laser cutting uses a high-powered thermal beam to cut materials, while a wire EDM uses electrical erosion from a wire.

Why is deionized water used in wire cut EDM?

Because of its low carbon property, deionized water is the dielectric medium used in wire EDM. It serves as a coolant to regulate the dielectric temperature.