Free 173 Best Homemade Tools eBook:  
Become a founding member: 500+ tool plans, full site access, and more.

User Tag List

Results 1 to 2 of 2

Thread: Odd-shaped plunge EDM electrode - photo

  1. #1
    Content Editor
    Supporting Member
    Altair's Avatar
    Join Date
    Aug 2013
    Posts
    2,274
    Thanks
    730
    Thanked 5,698 Times in 1,573 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)

  2. The Following 3 Users Say Thank You to Altair For This Useful Post:

    KustomsbyKent (08-01-2020), mwmkravchenko (07-29-2020), Scotsman Hosie (08-02-2020)

  3. #2
    Supporting Member KustomsbyKent's Avatar
    Join Date
    Dec 2014
    Location
    South Dakota
    Posts
    152
    Thanks
    1,256
    Thanked 119 Times in 68 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)

    KustomsbyKent's Tools
    This isn't so weird really... Walking through a plastic injection mold shop, and you'll see many weird electrodes for EDM.
    Plastic molds are made from hardened steel for longevity during the molding process. 50,000 shots to 200,000 shots...
    Some plastics are more abrasive than others, so hardened steels are a must. For example, a glass filled polycarbonate plastic used for automotive, and other high strength applications needs that hardened steel, as the glass wears on the mold during filling.
    Since the steel is hardened, it is much more difficult to machine features in.
    The solution is to use an EDM machine to burn the feature into the steel using the electro discharge machine. The electrode is made from copper, which is easy to machine. The downside to the whole process is that it's very slow!!!

    The steel molds get very expensive, especially for larger parts.
    China tooling for small parts can be fairly economical... Around $5000 for small parts.
    Complex and larger parts cause the cost to go up quickly... more tool steel, more machining, and a much larger mold press is needed during the manufacturing process. Those molds can cost over $250,000.... I know this first hand.

    So the next time you see a plastic part... whether it's on kid's toys, or your computer... each one of those parts has a corresponding steel mold to make that part.


    Post your reply!
    Join 42,532 of us and get 500+ tool plans, tool eBooks, build guides, and much more.



    eBooks for Supporters

Thread Information

Users Browsing this Thread

There are currently 1 users browsing this thread. (0 members and 1 guests)

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •