Open Source 3 Axis Wire-Cut EDM Machine

Basics

• Part of the Open Source Digital Fabrication Construction Set
• An electric discharge machining device (EDM)
• Uses a thin wire, and high voltage electricity to precisely erode away material using the resulting plasma
• Requires a wire feeding mechanism
• Good explanation + Demo in this video, at 13:26

Used For

• According to This :
  • Ideal for low volume quantities of parts that require tight manufacturing tolerances.
  • Extrusion dies.
  • Blanking punches.
  • Metal and tool fabrication.
• Also Really Small Stuff as shown in this video at 13:26

Industry Standards

Makino

• Site Link

MC Machines

• Site Link

Sodick

• Site Link

Existing Open Source Designs

"Action BOX"

• A Video by the YouTube Channel "Action BOX" Titled "DIY Wire EDM Machine | Cut through anything (conductive) with our CNC Electrical Discharge Machining"
  • As of this edit, the motion system is fine, they have it in a sort of "toolhead + bath" configuration working on an otherwise normal CNC Mill
  • All systems worked, but due to power supply spikes the wire was fully vaporizing and thus snapping
  • Solutions being suggested in the comments, but once a proper EDM Power Supply is used, it should work
  • Also water filtering needed

"Dominik Meffert"

• Their Hackaday Documentation of the Project
• Their YouTube Channel

Basic Design

Housing

• Holds all the below together

Controller

• Controls all components
• Raspberry Pi + Arduino + Any necessary shields?
• Connects to IO Panel and any external controls (PC, Server, WWW, etc)

IO Panel

• Touchscreen
• Optional Mouse + Keyboard

Fluid Pump

• Recirculates the dielectric fluid
• Does this to promote circulation
• Also provides pressure to debris clearing jets

Fluid Filter

• Cleans Debris (Such as Metal Dust) Out of the Dielectric Fluid
• Hydrocyclone + Standard Oil/Water Filter Cartridge
• Should also include sensors before and after filtration to determine fluid + filter effectiveness

Work Surface

• The Workpiece is attached to this

Fluid Bath

• Allows the Work Surface and Work Piece to be submerged in dielectric fluid
• Could be permanent or a slide up design

CNC Gantry

• Holds and Moves the Toolpiece
• Standard D3D Axis?

Toolpiece

• A device resembling two fingers holding dental floss
• Works with the power supply

Wire Feeder

• A device with two wire spools (one for feeding new wire thru and one for receiving spent wire)
• Also need to design/find the mechanism for shooting the string to the other side to remove the need for manual wire threading

Fluid Reservoir

• Holds Spare Fluid
• Also holds the contents of the fluid bath when not in use

Internal Links

• EDM

External Links

• Wikipedia Page on Electric Discharge Machining