EDM Cost Drivers
EDM pricing is opaque to most buyers. Unlike CNC milling where you can estimate cycle time from feeds and speeds, EDM cost depends on factors that aren't always obvious from the drawing.
Wire EDM Pricing
Wire EDM is typically quoted by linear inch of cut — total perimeter of all profiles multiplied by workpiece thickness. A 4" square cutout through a 2" thick block is 16 linear inches at 2" height = 32 square inches of cut area.
The variables that move price per inch: material type (carbide costs more than steel), number of skim passes (more passes = tighter tolerance = higher cost), workpiece height (taller = slower = more wire), and quantity (setup amortized across pieces).
Ballpark ranges: Simple profiles in tool steel at ±0.001" run $0.40–0.80 per square inch of cut area. Precision work at ±0.0002" runs $1.00–2.50 per square inch. Carbide adds 40–80%. These are rough frames — actual pricing depends on geometry, material, and shop capacity.
Sinker EDM Pricing
Less standardized because every job is unique. Major cost components: electrode fabrication (often 30–50% of total job cost), machine time ($75–150/hour depending on machine size), and setup and programming.
For repeat work, electrode cost amortizes — you make it once and use it for multiple parts (with replacement electrodes as they wear). First-article sinker EDM jobs are always expensive relative to production runs because of the electrode investment.
What Drives Cost Up
Tighter tolerances. Going from ±0.001" to ±0.0002" can double cut time — you're adding 3–4 skim passes. Only specify what your application actually requires.
Surface finish requirements. Mirror finishes (Ra <12 μin) require many slow finishing passes.
Exotic materials. Carbide, Inconel, and titanium cut slower and consume more wire. Material is the most predictable cost driver.
Tall workpieces. A 10" tall cut takes dramatically longer than a 1" tall cut of the same profile. Height is often the biggest surprise cost factor for buyers new to wire EDM.
Many start holes. Each internal cutout needs one. Fifteen features means fifteen start holes, each requiring positioning and drilling time.
What Drives Cost Down
Quantity. Setup time is fixed. Cutting 20 identical pieces costs far less per piece than cutting one.
Designing for the process. Edge access instead of start holes. Moderate tolerances where tight ones aren't needed. Consistent material thickness across features.
Talking to the shop first. A shop that can suggest modifications to make your part easier to cut will save you money every time. The best shops do this proactively.
The cheapest wire EDM job is one where the shop can load the part, hit start, and walk away. Anything that requires operator intervention during the cut — manual repositioning, wire re-threading after a break, flushing adjustments — adds cost because it ties up the operator and the machine simultaneously. Design parts that can run unattended and you'll get better pricing.
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