Several operational strategies can help moldmakers increase the value they reap from their EDM processes. In wire EDM, for example, the type of wire used can cut costs and improve efficiency. Brass is a commonly used and cost-effective wire material, but zinc-coated wire can increase speeds by up to 15 percent for improved productivity.

Moldmakers can optimize the process of starting from holes and edges with a few simple tips:
•    Use a thickness-adapting function for edge startup to avoid wire breakage.
•    Locate start holes as close to the cut profile to save lead-in time.
•    Starting from edges is best done on a submerged machine.
•    Utilize the auto-threader of the wire EDM to run as many cut openings as possible unattended.  Then the operator only has to spend time at the machine dropping slugs.

Preparing blanks is another important element of EDM that can save moldmakers time and money. Tricks such as leaving extra material for clamping; minimizing clamp and step heights when designing fixtures; and, keeping stacks as flat as possible can all optimize flushing pressure, which will improve machining efficiency.

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