Titanium Sinker EDM Machining for Aerospace and Medical Components

Background: Sinker EDM Requirements

Aerospace and medical components often feature complex cavities, intricate geometries, and fine details that are difficult to machine using conventional methods. Sinker EDM (Electrical Discharge Machining) provides a precise, low-force solution for such titanium parts.

In this case, the customer required titanium components with intricate cavities for aerospace assemblies and medical devices. Sinker EDM titanium machining was selected to achieve high accuracy without inducing mechanical stress.

Material Selection and Titanium Machinability

Titanium alloys were chosen for their high strength, corrosion resistance, and stability under demanding conditions. Machinability challenges included:

• Poor thermal conductivity leading to localized heat

• Tool wear in conventional machining

• Maintaining tight tolerances in complex cavities

EDM titanium machining eliminates cutting forces, making it ideal for precision cavities and fragile structures.

Sinker EDM Titanium Machining Process

Sinker EDM operations included:

• Machining internal cavities and pockets

• Maintaining fine features with precise electrode paths

• Controlling material removal rates to reduce thermal impact

Titanium sinker EDM provided repeatable accuracy and excellent surface quality for critical components.

Integration with CNC Titanium Machining

After sinker EDM, CNC titanium machining was applied to:

• Face milling for reference surfaces

• Drilling and tapping assembly holes

• Milling external geometries and mounting features

This hybrid approach ensured full functional integrity of machined titanium parts.

Dimensional Accuracy and Surface Quality

All critical dimensions were maintained within ±0.01 mm tolerance. Surface finishes were optimized for aerospace and medical standards, providing smooth cavities and clean edges.

Inspection and Quality Assurance

Inspection methods included:

• CMM measurement of cavities and external features

• Gauge verification of critical dimensions

• 100% visual inspection

These steps ensured all machined titanium parts met aerospace and medical quality standards.

OEM and Engineering Collaboration

Engineering teams collaborated to:

• Optimize EDM electrode design and machining parameters

• Plan integrated EDM and CNC sequences

• Validate prototypes before production

Supported CAD, CAM, and CAE tools included STEP, DWG, DXF, IGS, STL, and PDF formats.

Applications of Sinker EDM Titanium Components

Titanium sinker EDM machining is widely used for:

• Aerospace precision cavities and brackets

• Medical implant cavities and surgical device parts

• Industrial assemblies with intricate internal geometries

This approach enables highly accurate titanium parts where conventional machining is insufficient.

Conclusion

This case demonstrates how titanium sinker EDM machining combined with CNC titanium machining produces precise and reliable aerospace and medical components. By addressing titanium machinability challenges and integrating inspection protocols, high-quality machined titanium parts were delivered for complex applications.