XACT Wire EDM continues to serve as a reliable outsource EDM machining partner to manufacturers in a broad range of industries. Our engineering staff and machinists' understanding of materials and best EDM machining practices as they relate to individual applications is extensive. Below are examples of some of the commonest industries and applications our clients are engaged in.


medical device machining in Wisconsin and Illinois

Precision medical component projects have included femoral, tibial, resection cut blocks, endoscopic components, laparoscopic graspers & forceps, bone plates and other medical devices. We work with many materials like titanium, platinum, medical grade stainless steel, nitinol, tungsten.

Photonics & Optics

photonics technology manufacturers

Examples of projects include laser diode sub-mounts & arrays, heat sinks, optic collimators, Nano positioning parts & many other intricate parts requiring fine finishes & tolerances.

Power Generation & Turbines

turbine components manufacturers

Wire EDM is an ideal production machining method for cutting exotic materials that produces ready-to-use virtually burr-free parts. Typical metals include: Stainless steel, Inconel, Nickel-based super alloys, Kovar, Invar, Hastalloy & many other exotic materials.

Automation & Robotics

robotics component manufacturing

Complex parts, prototypes, robot components – (EOAT) end of arm tooling, gripper jaws and pinion gears are all parts that are typically produced in low volumes and are made of unique metals. These are ideal for EDM machining characteristics.


automotive industry machined parts

Electronic system modules, locking system components, hybrid & EV modules, fuel system components. XACT Wire EDM also produces components used in equipment on automotive production lines.

Cutting Tools

precision coolant hole machining for cutting tool manufacturers

We provide small hole EDM coolant holes in many components such as end mills, reamers, drills & routers. Materials such as carbide, high speed steels & many other hard to machine materials.

Energy / Renewable Energy

solar and power transmission components manufacturers

The projects in this industry need to be dependable & durable. Using our services we have worked on items such as solar energy cell components, deep cell battery tooling & molds, power transmission components.

Molding Industry

wire EDM machining for the injection molding industry

Wire EDM cutting and small hole EDM drilling are used to create core pins, mold slides, retainers and many other critical, intricately detailed parts for injection molds. XACT is the ideal partner for companies in the injection mold industry, and we often function as an extension of our clients’ in-house EDM capabilities.

Xact Wire EDM also is very experienced in additional industries including: Communication, Packaging


XACT Wire EDM also is very experienced in these types of applications. We work with many companies supporting these applications as an extension of their services so they can take on more business.

3D Printed Parts

wire EDM for additive manufacturing

Wire EDM is used to improve surface finish & tolerances of critical part features. It is also used to remove parts from the build plates & separate stacked parts.

CNC Parts

CNC parts

Our Wire EDM services are used in manufacturing CNC parts requiring narrow slots such as collets, small holes, difficult to machine materials, parts requiring a precise fits & tolerances.

Extrusion Dies & Sizing Plates

Extrusion die manufacturers

4-axis Wire EDM can be used to machine geometries consisting of two different shapes on parallel planes connected by a ruled surface. This is helpful for metal and plastic extrusion dies. Food processing nozzles can also be made using this capability. Any industry needing a tapered cut can benefit from this independent UV cutting.

Matched Metal Tooling

matched metal tooling

Click on the link above for a complete explanation and video. Wire EDM produces extremely small cutting clearances between the punch and die. This results in very good edge quality on final trimmed plastic parts.

Progressive, Fine Blanking & Compound Tooling

wire EDM used for progressive, fine blanking and compound tooling

Wire EDM has been used in these areas for many years. Tooling can be machined after heat treating. This results in extremely tight tolerances being held. Geometry can be machined in one setup and taper relief with land can be introduced where required.

Additional applications we provide wire EDM services for include:

Metal Injection Molded Parts (MIM) – Our services are used for needed surface finishes and tolerance improvements.

Powdered Metal Parts & Tooling – Our services are used in tooling for sizing & on parts that need better surface finishes and tolerances.

Wondering if wire EDM is right for your project? Check out our guide to wire EDM vs CNC milling or contact us with questions.