EDM

At Thaler Defense Systems, wire EDM is a strategic capability embedded in our advanced manufacturing workflows to unlock complex geometries, maintain material integrity and enable ultra-precision results where traditional machining alone falls short.

Used selectively within our integrated process chains, wire EDM allows us to achieve exacting tolerances, sharp internal features and intricate profiles in high-strength and heat-treated materials — without compromising part quality or stability. Count on our wire EDM machining services for custom parts to deliver the highest level of accuracy even in complex metalworking.

What Is Wire EDM?

Wire electrical discharge machining (wire EDM) is a non-contact thermal process that uses electrically charged wire to erode conductive materials with exceptional precision. Guided by CNC controls, it is ideal for machining features such as:

Tight-tolerance internal profiles
Ultra-fine edges and thin walls
Deep cavities and complex contours
Precision cuts in hardened alloys

Because there are no cutting forces, wire EDM is perfect for delicate or high-hardness components where distortion control is critical. Choose our EDM machining for custom tooling and mold fabrication that ensures ultra-high precision and strict tolerance.

Strategic Application in Defense Manufacturing

Material integrity is indispensable in the aero-defense sector. Our wire EDM plays a critical role in enabling precision outcomes across a range of aerospace and defense assemblies. Whether producing thin-wall motor cases, intricate housings or geometrically challenging interfaces, EDM complements downstream milling, turning and grinding operations to deliver mission-ready parts that meet:

Sub-micron accuracy and surface finish requirements
High thermal and structural performance
Strict geometric tolerances in high-hardness materials
Lightweight and complex architectures for flight and space systems

Wire EDM is particularly valuable in producing features that cannot be machined conventionally, helping our customers meet performance, weight and manufacturability goals with confidence.

Integrated Process. Trusted Results.

Choose us for advanced manufacturing methods and innovative technologies for a mission success. As a major defense contractor, we excel in the production of metals where precision and efficiency can be tricky. Our EDM capability is fully integrated with our inspection, quality and final machining processes, ensuring seamless part flow, traceability and consistency at every step.

Our investment in advanced EDM technology and certified operators supports:

Full life cycle part production — from prototype through full-rate manufacturing

Repeatable, lights-out precision with minimal variation

Complex part features without compromising material integrity

Cross-functional manufacturability engineering and process development

By implementing EDM into our manufacturing process, you can rely on us to deliver high-performing parts, intricate components and precision pieces critical for rocket engines.

Partner with Thaler Defense Systems for Superior Defense Solutions

Coordination to gather any necessary technical data or documentation

Optional in-person or virtual meeting to review project requirements

A detailed, timely quote prepared by our business development and engineering teams

Complete confidentiality—your information is secure and never shared

Certifications

General Dynamics Supplier of Excellence Award

Certified ISO 9001:2015 Fifth Edition

TMC Supplemental Quality Assurance Requirements

General Dynamics Supplier of Excellence Award

Certified AS9100: 201 Rev D

Achieve Precision and Maximum Efficiency With the Help of Aero-Defense Leaders

Wire EDM at Thaler is not just precision — it’s precision with purpose. Our EDM machining services meet your most demanding manufacturing requirements and most challenging materials with rigorous quality control measures in place. Trust our reliable EDM machining for aerospace parts, serving the demands of national security and global defense systems and achieving high precision even with complex outlines, thin materials or tough, heat-treated surfaces. Contact us today to learn how Thaler Defense Systems integrates wire EDM into system-level manufacturing strategies that deliver for the warfighter.

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EDM Capabilities

EDM