ARISTECH EDM technology: high-precision electrical discharge machining for mould and die
The mould and die sector is, by definition, one of the most demanding in the metalworking industry. Manufacturing injection moulds, stamping dies or progressive dies requires a level of dimensional accuracy, surface finish and ability to work intricate geometries that often exceeds the limits of conventional metal-cutting processes.
This is where non-conventional technologies, and in particular electrical discharge machining (EDM), become indispensable.
To compete in this sector, a good machine is not enough; you need an advanced, reliable technological solution optimised for this application. That is why we have full confidence in the technology of ARISTECH, a specialist in EDM machines.
What is electrical discharge machining (EDM)?
Unlike milling or turning, EDM does not rely on physical contact with a cutting tool. It is a thermal process that removes material through a series of controlled electrical discharges (sparks) that jump between an electrode (the "tool") and the workpiece, both immersed in a dielectric fluid.
The great advantage of this method is that the hardness of the material is no obstacle, as long as it is electrically conductive. This makes it possible to machine hardened steels, cemented carbides and special alloys that would be impossible or uneconomical to work with traditional methods.
Why mould and die making needs EDM
The end product of a mould (whether a plastic part, an automotive component or a medical device) is a direct reflection of the quality of its cavity. Mould makers face three major challenges every day:
- High-hardness materials: moulds must withstand thousands or millions of cycles. They are made from heat-treated steels (above 50-60 HRC) to ensure durability.
- Complex geometries: thin ribs, internal corners with minimal radii, negative draft angles or deep, narrow cavities are impossible to produce with a milling cutter.
- Surface finishes (Ra): many moulds, especially those for optics or cosmetic components, require mirror finishes (very low Ra). Manual polishing is expensive and slow, and it can introduce dimensional errors.
The precise solution for the mould shop
ARISTECH EDM machines are designed to meet these challenges, establishing themselves as a benchmark in the sector. Their technology focuses on delivering maximum accuracy and efficiency.
Die-sinking EDM
For creating complex cavities, ARISTECH die-sinking EDM is essential. Using an electrode (usually graphite or copper) with the inverse shape of the desired cavity, the machine "burns" into the hardened steel with micrometric precision.
The key to ARISTECH technology lies in its latest-generation generators. These control the energy, frequency and duration of each spark, enabling:
- Unrivalled finishes: the ability to optimise the gap (the distance between electrode and workpiece) and the spark power allows ARISTECH to achieve excellent surface finishes, drastically reducing or eliminating the need for costly hours of manual polishing.
- Minimal electrode wear: superior process control ensures that the electrode wears less, allowing complete cavities to be machined with a single electrode and guaranteeing repeatability in multi-cavity moulds.
Wire EDM (wire-cut)
For cutting precise contours, punches, inserts and ejectors, ARISTECH wire EDM is the solution. A fine wire (usually brass) cuts the material with extreme precision.
The thermal stability and rigidity of ARISTECH machines ensure high-precision cuts on very thick parts, which is essential for cutting and stamping dies.
The added value in mould machining
Integrating ARISTECH technology into a mould and die shop is not just about acquiring a machine; it means adopting a process that makes it possible to:
- Make the impossible: tackle geometries that competitors cannot mill.
- Reduce cycle times: by machining directly on hardened material, intermediate steps are eliminated and fitting and polishing hours are reduced.
- Assure quality: guarantee the dimensional accuracy and surface finish demanded by sectors such as automotive, medical and packaging.
At Ferrotall, we provide not only advanced ARISTECH machinery but also the technical support and process knowledge needed to successfully integrate high-precision EDM into your workflow, ensuring that every mould and die meets the most demanding specifications.