Creating 3D CAD models is only the beginning. Without optimisation for wire EDM or CNC milling, the design may extend production time, increase cost and require rework. A well-optimised CAD model can reduce cutting time by up to 40%.

⚙️ Why Is CAD Optimisation Critical?

Every additional geometric feature in the model means more EDM cutting time and more work in PEPS CAM. Overly complex details make programming harder and increase error risk. Simple CAD model = faster production + lower cost.

📐 What to Optimise in a CAD Model?

1. Geometry and Contours

Avoid small, non-essential details. Radius sharp corners. Simplify narrow slots. Result: shorter EDM cutting time and fewer CNC milling issues.

2. Wall Thickness

Minimum and maximum thickness should match machine capabilities. Too thin = risk of damage; too thick = longer machining time.

3. Parametric Model Parameters

Use parametric relationships and dimensions in SolidWorks and MegaCAD — easy changes to critical dimensions when requirements change.

4. Tolerances and Accuracy

Apply tolerances only where needed. Overly tight tolerances throughout → slower cutting, higher cost. Optimisation maintains quality at lower cost.

5. Units and Scale

Always use consistent units (mm) and avoid conversion errors between CAD systems.

🧩 Best Optimisation Practices for Wire EDM/CNC

  • Simplify geometry without losing function — this is the biggest saving
  • Close all contours and surfaces — mandatory for PEPS CAM
  • Check for narrow slots and sharp corners
  • Use parametric models — changes in minutes, not hours
  • Consult critical features with the EDM operator before finalising the design

⚠️ Common Optimisation Mistakes

  • Leaving decorative details that serve no production purpose
  • Missing closed contours — most common error causing file rejection by CAM
  • Overly complex model structure making CAM programming difficult
  • Ignoring machine capabilities (minimum wire EDM radius, minimum CNC end mill radius)

🏭 Real-World Example — Actual Savings

A designer prepares a wire EDM die. Original model: too many sharp corners, narrow slots, unnecessary details. After optimisation (simplified contours, radiused corners, minimised details) — cutting time reduced by 40%, machining cost significantly lower — with the same part functionality.

💡 Simple rule: The simpler and more thoughtfully designed the CAD model, the better the results in wire EDM and CNC production. Every minute spent on design optimisation saves many minutes of machine time.