One of the most common questions when ordering wire EDM: how much does it cost? The problem is that there is no single answer. Two companies may quote completely different prices for the same part — and both can be right. Why? Because the cost of wire EDM depends not on one factor, but on the entire process.
🤔 Why Is There No Fixed Price?
Unlike simple services, there is no "price per metre" here. Every part is different — different geometry, different material, different quality requirements. This is why every job is quoted individually.
⏱️ The Key Factor: Machine Time
The basis for pricing is machine running time. The longer the cut, the higher the cost. Time depends on cut length, material thickness and settings. Two visually similar parts can have very different machining times.
🧱 Material and Thickness
Not every material cuts at the same speed. Aluminium and copper are fast; hardened steel and carbides are significantly slower. Thickness has a direct impact on cutting time — the difference between a thin and thick part can be enormous even with identical geometry.
🔬 Surface Quality and Number of Passes
| Required Quality | Passes | Cost Impact |
|---|---|---|
| Low (Ra 3.2) | 1 pass | Lowest |
| Medium (Ra 1.6) | 2–3 passes | Medium |
| High (Ra 0.4) | 4–6 passes | High |
⚙️ Part Complexity
A simple shape can be cut quickly. If the part has sharp corners, small radii or complex contours, the process becomes slower. Process instability (wire breaks, stoppages) also increases time and cost.
💡 Why Prices Differ Between Companies
Differences come from operator experience, quality of settings, process efficiency and overall approach. One company may complete a part faster, more stably and with fewer errors — which directly translates to a lower price. Is the cheapest offer the best? Not always — a low price may mean lower quality or poor repeatability.
💰 How to Lower the Cutting Cost
- Simplify the geometry — where possible without losing functionality
- Provide a CAD file — a ready DXF saves preparation time
- Match tolerances to requirements — don't specify ±0.002 mm when ±0.01 mm is enough
- Order a larger batch — unit cost drops with higher quantities
- Consult before production — a small design change can bring significant savings