{"id":11768,"date":"2026-06-16T18:36:53","date_gmt":"2026-06-16T10:36:53","guid":{"rendered":"https:\/\/www.cncmachiningshops.com\/?p=11768"},"modified":"2026-07-15T22:09:36","modified_gmt":"2026-07-15T14:09:36","slug":"wire-edm-vs-sinker-edm","status":"publish","type":"post","link":"https:\/\/www.cncmachiningshops.com\/tr\/wire-edm-vs-sinker-edm\/","title":{"rendered":"Tel EDM ve Dald\u0131rma EDM: Hangi \u0130\u015fleme Y\u00f6ntemini Se\u00e7melisiniz?"},"content":{"rendered":"
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Quick Answer:<\/strong> Wire EDM and sinker EDM (ram EDM, die-sinking EDM) use the same electrical discharge erosion principle but solve different geometry problems. Wire EDM feeds a continuously moving wire electrode (typically 0.10\u20130.30 mm diameter) through the workpiece along a CNC-programmed path, producing two-dimensional through-cut profiles \u2014 the wire must have entry and exit access through the workpiece thickness. Sinker EDM uses a pre-machined solid electrode (graphite or copper) shaped to the negative of the desired cavity, which erodes material by advancing into the workpiece surface \u2014 the process is not limited to through-cuts and is the standard method for blind pockets, internal cavities, deep ribs, and complex mold features. Typical tolerance: wire EDM \u00b10.002\u20130.005 mm; sinker EDM \u00b10.005\u20130.010 mm. The selection is driven by geometry accessibility \u2014 the question is whether the feature requires a through-cut (wire EDM) or an enclosed\/blind cavity (sinker EDM). Both processes machine hardened materials without cutting force, independent of workpiece hardness.<\/p><\/blockquote>\n

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The Fundamental Difference: Through-Cut vs Cavity Formation<\/h2>\n

Wire EDM and sinker EDM are not competing for the same machining tasks \u2014 they solve geometrically distinct problems.<\/p>\n

Wire EDM \u2014 precision through-cut profiling:<\/strong> The wire electrode is threaded through a pre-drilled start hole and fed through the workpiece by CNC-controlled X-Y table movement, maintaining a controlled gap (~0.01\u20130.05 mm) between the wire and the workpiece wall. The wire erodes the workpiece along its path, producing a kerf of width equal to the wire diameter plus twice the spark gap (~0.12\u20130.40 mm total kerf for standard 0.20 mm wire). The CNC control programs any two-dimensional profile, including complex curves, sharp re-entrant corners, and multiple closed contours in a single setup. The process is geometrically limited: the wire must have a clear path from entry point to exit point through the workpiece. It cannot produce blind pockets, cavities with closed tops, or features inaccessible from above and below.<\/p>\n

Sinker EDM \u2014 electrode-defined cavity formation:<\/strong> The sinker EDM electrode is pre-machined to the negative shape of the desired cavity \u2014 a graphite or copper block machined by CNC milling to the profile that, when eroded into the workpiece, produces the intended feature. The electrode advances into the workpiece surface (the “sinking” motion) while electrical sparks erode material from the workpiece surface in the shape of the electrode face. Multiple electrodes are typically used in sequence: a roughing electrode removes most material at high spark energy, followed by semi-finishing and finishing electrodes at progressively lower energy settings to achieve dimensional accuracy and surface finish. The process can produce blind pockets, enclosed internal features, undercuts, and three-dimensional cavity forms that wire EDM cannot access.<\/p>\n

The practical consequence:<\/strong> A stamping die insert requires both a through-profile (the cutting edge contour \u2014 wire EDM) and a clearance relief that opens inward from the cutting edge (sinker EDM or CNC). A typical injection mold insert uses sinker EDM for the cavity geometry and wire EDM for the insert’s external profile and through features. These are complementary processes used at different stages of the same component’s production.<\/p>\n

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Process Capabilities Compared<\/h2>\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n\n
Factor<\/th>\nWire EDM<\/th>\nSinker EDM<\/th>\n<\/tr>\n<\/thead>\n
Tool<\/td>\nContinuously fed brass wire, \u00d80.10\u20130.30 mm<\/td>\nPre-machined electrode (graphite or copper)<\/td>\n<\/tr>\n
Geometry type<\/td>\n2D through-profiles; tapers up to \u00b130\u00b0<\/td>\n3D cavities; blind pockets; internal features<\/td>\n<\/tr>\n
Through-access requirement<\/td>\nMandatory (wire must pass completely through)<\/td>\nNot required (electrode advances from surface)<\/td>\n<\/tr>\n
Blind features<\/td>\nNot possible<\/td>\nStandard capability<\/td>\n<\/tr>\n
Achievable tolerance<\/td>\n\u00b10.002\u20130.005 mm<\/td>\n\u00b10.005\u20130.010 mm<\/td>\n<\/tr>\n
Surface finish (multiple passes)<\/td>\nRa 0.4\u20131.6 \u00b5m<\/td>\nRa 0.2\u20131.2 \u00b5m (finishing passes)<\/td>\n<\/tr>\n
Minimum internal corner radius<\/td>\n~0.06\u20130.15 mm (wire radius + spark gap)<\/td>\nDepends on electrode geometry<\/td>\n<\/tr>\n
Electrode\/tool preparation<\/td>\nNone (standard wire from spool)<\/td>\nElectrode must be CNC machined; separate time and cost<\/td>\n<\/tr>\n
Material removal rate<\/td>\nTypically 20\u2013200 mm\u00b2\/min (cut area per minute)<\/td>\nTypically 0.1\u20135 cm\u00b3\/hour<\/td>\n<\/tr>\n
Hardness limitation<\/td>\nNone (independent of workpiece hardness)<\/td>\nNone<\/td>\n<\/tr>\n
Primary applications<\/td>\nDies, punches, profile inserts, precision slots<\/td>\nMold cavities, blind pockets, ribs, internal features<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n
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When Wire EDM Is the Correct Choice<\/h2>\n

Wire EDM is the correct process when the feature geometry can be described as a two-dimensional profile cut through the workpiece thickness, and when dimensional accuracy and sharp profile geometry are the primary requirements.<\/p>\n

Stamping dies and punches:<\/strong> The cutting edge profile of a stamping die or punch must be produced in hardened tool steel (HRC 58\u201365) with sharp corners approaching 0\u00b0 radius and tolerances of \u00b10.002\u20130.005 mm. Wire EDM cuts this profile directly in the hardened state \u2014 no re-annealing is required and no secondary grinding of the edge is needed. The corner radius achievable is approximately equal to the wire radius plus the spark gap: with 0.10 mm wire, internal corners of approximately 0.07\u20130.10 mm radius are achievable. CNC machining cannot produce these corners in hardened tool steel, and conventional grinding cannot produce complex curved profiles efficiently.<\/p>\n

Progressive die inserts:<\/strong> Progressive stamping dies consist of multiple insert sections, each with a specific through-profile geometry that must match the adjacent sections within \u00b10.003\u20130.005 mm. Wire EDM, programmed from the die design file, produces each section to the required profile with the accuracy and consistency that assembly requires. The process is the industry standard for progressive die production.<\/p>\n

Precision gauges and fixtures:<\/strong> Precision gauge inserts, jig bushings, and inspection fixtures require through-profile accuracy of \u00b10.002\u20130.003 mm at locations that must be relative to established datum features. Wire EDM, using the part’s machined datum features as the setup reference, produces the gauge profiles with the required positional accuracy in a single setup.<\/p>\n

Medical and aerospace through features:<\/strong> Thin components in titanium, stainless steel, and high-nickel alloys with complex through profiles, slots, or wire-EDM starting holes require the no-cutting-force advantage of wire EDM. Titanium’s tendency to spring back elastically after cutting, and its low ductility, makes it particularly susceptible to burring and edge damage from mechanical cutting \u2014 wire EDM eliminates these risks.<\/p>\n

What wire EDM cannot do:<\/strong> Wire EDM cannot produce any feature that does not have through access from the top and bottom of the workpiece. Blind pockets, enclosed internal features, cavities with solid floors, undercut features not accessible in the taper angle range of the machine, and three-dimensional surface contours requiring simultaneous three-axis motion are all outside wire EDM’s geometric capability.<\/p>\n

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When Sinker EDM Is the Correct Choice<\/h2>\n

Sinker EDM is the correct process \u2014 and frequently the only viable process \u2014 when the feature is a blind pocket, enclosed cavity, or three-dimensional internal form that wire EDM cannot access.<\/p>\n

Injection mold cavities:<\/strong> The primary cavity of an injection mold is a three-dimensional enclosed volume in hardened tool steel (P20 at HRC 30\u201334 or H13 at HRC 48\u201352). CNC milling is used for roughing and semi-finishing before hardening; sinker EDM finishes the cavity geometry after hardening, adding sharp corners and fine surface texture that the minimum milling tool radius cannot achieve. The sinker EDM electrode is machined from graphite (most common for steel molds) to the positive shape of the cavity, and the erosion produces the negative of that shape in the mold.<\/p>\n

Deep ribs and narrow internal features:<\/strong> Mold cavities for ribbed plastic parts, heat sink cores, and precision instrument housings contain ribs that are 0.5\u20132 mm wide and 10\u201330 mm deep. CNC end mills attempting to machine these features at depth experience vibration, tool deflection, and breakage. Sinker EDM electrodes, with no cutting force, produce these ribs with consistent geometry and smooth surfaces (Ra 0.4\u20130.8 \u00b5m with finishing passes) regardless of rib depth.<\/p>\n

Blind holes and pockets:<\/strong> A cylindrical or non-circular blind pocket \u2014 a pocket that does not penetrate through the workpiece \u2014 is a sinker EDM application by definition if it requires tight tolerance or a non-circular profile. Circular blind holes are drilled; non-circular blind features, or circular blind features requiring \u00b10.010\u20130.020 mm floor flatness, use sinker EDM.<\/p>\n

Internal splines and keyways:<\/strong> Internal splines on coupling hubs and gear bores, where broaching tooling is not economically justified for small quantities, are produced by sinker EDM using a profiled electrode. The electrode profile matches the spline tooth form; the electrode advances into the bore producing the spline geometry.<\/p>\n

The electrode cost consideration:<\/strong> Every sinker EDM job requires electrode preparation \u2014 CAD model of the electrode, CNC machining of the electrode (typically 0.5\u20134 hours for moderate complexity), and electrode qualification. A simple blind pocket with a rectangular cross-section and moderate tolerance might require one roughing electrode; a complex mold cavity with multiple ribs, radii, and texture requirements might require 3\u20136 electrodes. Electrode preparation cost is a fixed overhead per job that makes sinker EDM less economical than wire EDM for simple geometry where wire EDM is applicable.<\/p>\n

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Tolerance and Surface Finish Details<\/h2>\n

Wire EDM tolerance mechanisms:<\/strong> Wire EDM achieves its tight tolerances (\u00b10.002\u20130.005 mm) through the absence of cutting force (eliminating tool deflection error), the small spark gap (controlled by machine parameters to approximately 0.010\u20130.030 mm), and multiple skim passes. The first (roughing) pass removes most material; subsequent skim passes reduce the remaining spark crater roughness and refine the dimensional position. With three passes, a wire EDM process typically achieves Ra 0.8\u20131.6 \u00b5m and \u00b10.003\u20130.005 mm. With four to five passes, Ra 0.4\u20130.8 \u00b5m and \u00b10.002\u20130.003 mm are achievable on precision machines.<\/p>\n

Sinker EDM tolerance mechanisms:<\/strong> Sinker EDM dimensional accuracy depends on: the electrode-to-workpiece spark gap (controlled by discharge energy); the electrode wear ratio (amount of electrode material removed per unit of workpiece material removed, typically 0.1\u20132% for graphite electrodes, requiring compensation in electrode programming); and the accuracy of the electrode itself (machined to \u00b10.005\u20130.010 mm). Each sinker EDM pass uses different discharge parameters: roughing (high energy, fast material removal, Ra 3.2\u20136.3 \u00b5m), semi-finishing (medium energy, Ra 1.6\u20133.2 \u00b5m), and finishing (low energy, Ra 0.4\u20131.6 \u00b5m). The electrode geometry is offset from the final part geometry by the spark gap plus compensation amount, requiring precise programming.<\/p>\n

Corner capability comparison:<\/strong> Wire EDM’s minimum internal corner radius is approximately equal to the wire radius plus the spark gap distance \u2014 approximately 0.07\u20130.15 mm for 0.10\u20130.20 mm wire. For dies and gauges requiring very sharp internal corners, wire EDM provides the best corner geometry of any machining process. Sinker EDM’s corner capability depends on the electrode geometry \u2014 the electrode can be machined with very small radii, and the resulting cavity corner approximately matches the electrode corner minus the spark gap. For concave corners in cavities (convex corners on the electrode), sinker EDM also achieves near-sharp geometry.<\/p>\n

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Cost Analysis<\/h2>\n

Wire EDM economics:<\/strong> Wire EDM has no electrode preparation cost \u2014 the wire is a standard consumable (approximately $0.10\u2013$0.50 per meter of wire consumed). The cost drivers are machine time (cutting speed decreases with workpiece thickness and tighter tolerance) and part complexity (longer programmed path = longer cut time). For a simple rectangular die profile in 20 mm thick D2 tool steel, wire EDM might take 2\u20133 hours including setup; a complex progressive die insert might take 8\u201315 hours. Wire EDM is economical for high-precision through-profiles of any complexity and is typically the lowest-cost option when the geometry is accessible.<\/p>\n

Sinker EDM economics:<\/strong> Sinker EDM has an electrode preparation overhead of approximately $100\u2013$1,500 per setup depending on electrode complexity. A simple rectangular pocket electrode is machined in 30\u201360 minutes of CNC time; a complex mold cavity electrode with multiple ribs and radii may require 4\u201310 hours of CNC time plus operator qualification time. This fixed overhead makes sinker EDM less economical than wire EDM for simple features, but competitive for complex cavities where no alternative process can achieve the required geometry.<\/p>\n\n\n\n\n\n\n\n\n\n\n
Feature Type<\/th>\nMore Economical Process<\/th>\nReason<\/th>\n<\/tr>\n<\/thead>\n
Simple rectangular or contour profile (through)<\/td>\nWire EDM<\/td>\nNo electrode needed; direct cutting<\/td>\n<\/tr>\n
Complex contour profile in hardened steel<\/td>\nWire EDM<\/td>\nNo electrode overhead; cuts any profile<\/td>\n<\/tr>\n
Simple blind rectangular pocket<\/td>\nCNC machining (preferred); sinker EDM if tolerance requires<\/td>\nCNC is faster and cheaper for accessible geometry<\/td>\n<\/tr>\n
Complex mold cavity with ribs, after hardening<\/td>\nSinker EDM<\/td>\nCNC cannot reach after hardening; geometry requires electrode<\/td>\n<\/tr>\n
Internal spline, small quantity<\/td>\nSinker EDM<\/td>\nBroaching tooling cost not justified; electrode is practical<\/td>\n<\/tr>\n
Progressive die components<\/td>\nWire EDM<\/td>\nStandard process; no electrode required<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n
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Common Mistakes in EDM Process Selection<\/h2>\n\n\n\n\n\n\n\n\n\n
Mistake<\/th>\nConsequence<\/th>\nCorrect Approach<\/th>\n<\/tr>\n<\/thead>\n
Specifying wire EDM for a blind cavity<\/td>\nImpossible to machine \u2014 wire has no exit path<\/td>\nIdentify whether feature has through access; if not, specify sinker EDM<\/td>\n<\/tr>\n
Specifying sinker EDM for a simple through-cut profile<\/td>\nUnnecessary electrode preparation cost; 2\u20135\u00d7 higher cost than wire EDM<\/td>\nUse wire EDM for through-profile geometry; reserve sinker EDM for inaccessible features<\/td>\n<\/tr>\n
Ignoring electrode preparation cost in sinker EDM quotations<\/td>\nActual cost 30\u201370% higher than machining cost alone<\/td>\nRequest full quote including electrode design, machining, and qualification time<\/td>\n<\/tr>\n
Assuming wire EDM and sinker EDM are interchangeable<\/td>\nWrong process selected based on familiarity<\/td>\nDetermine whether feature is through or blind before specifying EDM type<\/td>\n<\/tr>\n
Not specifying taper in wire EDM when required<\/td>\nVertical walls produced where tapered walls are needed (or vice versa)<\/td>\nSpecify any required draft or taper angle in drawing; wire EDM supports \u00b115\u201330\u00b0 taper depending on machine<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n
\n

Key Takeaways<\/h2>\n
    \n
  • The primary selection criterion between wire EDM and sinker EDM is geometry accessibility<\/strong>: wire EDM requires a through-cut path; sinker EDM operates from the workpiece surface and can produce blind features. This distinction is not about precision preference \u2014 it is about geometric feasibility.<\/li>\n
  • Wire EDM achieves \u00b10.002\u20130.005 mm tolerance<\/strong> on through-profile dimensions with surface finish Ra 0.4\u20131.6 \u00b5m after multiple skim passes. The minimum internal corner radius is approximately 0.07\u20130.15 mm, making it the best process for sharp corners in through profiles.<\/li>\n
  • Sinker EDM achieves \u00b10.005\u20130.010 mm tolerance<\/strong> on cavity dimensions, with surface finish Ra 0.2\u20131.2 \u00b5m with finishing passes. Accuracy depends on electrode geometry accuracy and spark gap compensation programming.<\/li>\n
  • Both processes machine hardened materials without cutting force<\/strong>: this is the shared advantage that makes both EDM types applicable to tool steels at HRC 60\u201365, titanium, Inconel, and other hard or difficult-to-machine materials where conventional cutting produces rapid tool wear.<\/li>\n
  • Wire EDM has lower per-job overhead than sinker EDM<\/strong> for through profiles because no electrode preparation is required. Sinker EDM has higher fixed overhead (electrode design, machining, and qualification) but is the only viable process for enclosed cavities and complex blind features.<\/li>\n
  • Many precision components require both processes<\/strong>: the external profile and through features use wire EDM; the internal cavities and blind ribs use sinker EDM. These are complementary processes typically applied at different stages of the same workpiece’s production.<\/li>\n
  • For OEM procurement and design teams<\/strong>: when specifying EDM on engineering drawings, the drawing should indicate which features are through-cut (wire EDM applicable) and which are blind or enclosed (sinker EDM required), and the tolerance and surface finish requirements for each. A note such as “wire EDM, profile to \u00b10.003 mm” or “sinker EDM cavity, Ra \u22641.6 \u00b5m after finishing” provides the supplier the information needed to quote accurately and select the correct process without ambiguity.<\/li>\n<\/ul>\n
    \n

    Frequently Asked Questions<\/h2>\n

    What is the main difference between wire EDM and sinker EDM?<\/h3>\n

    Wire EDM uses a continuously moving wire electrode to cut two-dimensional profiles completely through the workpiece \u2014 the wire must enter and exit the workpiece, making it applicable only to through-cut features. Sinker EDM uses a pre-machined solid electrode to erode material from the workpiece surface by advancing (sinking) into it \u2014 the process is not limited to through-cuts and can produce blind pockets, enclosed cavities, deep ribs, and three-dimensional internal features. Both processes use electrical discharge erosion, both are independent of workpiece hardness, and both produce no cutting force. The selection between them is determined by whether the feature has through access (wire EDM) or requires access from only one side (sinker EDM).<\/p>\n

    Can wire EDM machine blind cavities?<\/h3>\n

    No. Wire EDM requires the wire to pass completely through the workpiece from entry to exit \u2014 the wire cannot turn back on itself or enter a closed cavity. Any feature that does not have through access (a pocket with a solid floor, an enclosed internal feature, a blind hole with a non-circular profile) cannot be produced by wire EDM. These features require sinker EDM, where the shaped electrode advances from the workpiece surface to erode the cavity form. In some cases, CNC machining before hardening can be used for blind features, with sinker EDM reserved for the features that CNC cannot complete after hardening.<\/p>\n

    Which is more accurate \u2014 wire EDM or sinker EDM?<\/h3>\n

    Both are highly accurate, but they achieve accuracy through different mechanisms. Wire EDM typically achieves \u00b10.002\u20130.005 mm through the absence of cutting force, controlled spark gap, and multiple skim passes. Sinker EDM typically achieves \u00b10.005\u20130.010 mm, where accuracy depends on electrode geometry accuracy, spark gap compensation, and electrode wear ratio management. Wire EDM’s accuracy is more inherent to the process parameters; sinker EDM accuracy requires additional engineering in electrode preparation. For through-profile features, wire EDM is generally more accurate; for enclosed cavities, sinker EDM provides the only accurate option.<\/p>\n

    Why does sinker EDM require electrode preparation?<\/h3>\n

    Sinker EDM erodes material in the shape of the electrode face \u2014 the electrode is machined to the positive shape of the desired cavity, and the workpiece receives the negative. Without a shaped electrode, sinker EDM cannot produce any defined geometry. Electrode preparation involves: modeling the electrode geometry in CAD (accounting for spark gap offset and electrode wear compensation), CNC machining the electrode from graphite or copper stock, and qualifying the electrode dimensions before use. For complex geometries, 3\u20136 electrodes of different energy levels (roughing, semi-finishing, finishing) may be required. This fixed overhead per job makes sinker EDM less economical for simple geometry where wire EDM is applicable.<\/p>\n

    When should I choose wire EDM over conventional CNC machining?<\/h3>\n

    Wire EDM should be chosen over CNC machining when: the material is hardened above approximately HRC 45\u201350, where CNC tool wear becomes rapid and dimensional accuracy is difficult to maintain; the required internal corner radius is smaller than the smallest practical CNC end mill (approximately 0.5 mm for production CNC milling vs 0.07\u20130.15 mm for wire EDM); the part is thin or delicate and mechanical cutting force would cause deflection or distortion; or the tolerance required (\u00b10.002\u20130.005 mm) cannot be consistently achieved by CNC machining for the feature type. For soft-to-medium hardness materials with features above 0.5 mm corner radius and tolerances above \u00b10.010 mm, CNC machining is typically faster and less expensive than wire EDM.<\/p>\n

    \n

    Written by the CMS engineering team with 15+ years of precision CNC machining experience including coordination of wire EDM and sinker EDM operations for stamping die components, injection mold inserts, precision gauging, aerospace fixtures, and medical device components in tool steel, stainless steel, titanium, and Inconel. Technical references: Masuzawa T. \u2014 State of the Art of Micromachining (EDM processes), ASM Handbook Vol. 16 (Machining \u2014 Electrical Discharge Machining), Laermer F. and Schilp A. \u2014 Bosch DRIE Patent (for comparison of EDM geometry with other precision processes), GF Machining Solutions Wire EDM and Sinker EDM Application Guides, Machinery’s Handbook (Electrical Discharge Machining).<\/em><\/p>\n

    \n

    Sourcing Precision EDM Machined Components?<\/strong><\/p>\n

    At CMS, we coordinate wire EDM and sinker EDM operations for stamping dies, mold inserts, precision gauging, and aerospace\/medical components \u2014 with tolerance capability to \u00b10.003 mm, surface finish Ra 0.4\u20130.8 \u00b5m, and full CMM dimensional reports.<\/p>\n

    [Request an EDM specification review and precision machining quote \u2192]<\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"

    Wire EDM vs sinker EDM: through-cut vs cavity machining, tolerances \u00b10.002\u20130.010 mm, electrode cost, mold & die applications & geometry-based selection guide.<\/p>","protected":false},"author":1,"featured_media":11871,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"footnotes":""},"categories":[104],"tags":[],"class_list":["post-11768","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-general-basics"],"yoast_head":"\nWire EDM vs Sinker EDM: Which Process to Choose?<\/title>\n<meta name=\"description\" content=\"Wire EDM vs sinker EDM: through-cut vs cavity machining, tolerances \u00b10.002\u20130.010 mm, electrode cost, mold & die applications & geometry-based selection guide.\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" 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