For mold manufacturers, precision machining is the cornerstone of product quality, and Wire Electrical Discharge Machining (Wire EDM) plays an irreplaceable role in achieving high-precision, complex mold components. When collaborating with a mold processing factory, one of the most concerned issues for customers is: How is the pricing of Wire EDM processing determined?
Unlike some vague pricing models in the machining industry, Wire EDM pricing follows a scientific and transparent logic, mainly based on processing characteristics such as cutting area or processing time, and is adjusted according to factors like material, precision requirements, and process complexity. Today, we will comprehensively decode the pricing mechanism of Wire EDM processing to help you better plan your mold processing budget and choose the most cost-effective processing solution.
1. The Most Common Pricing Method: By Cutting Area
For most standard mold Wire EDM projects, pricing based on cutting area is the mainstream and most intuitive method. The core logic is to calculate the total cost by multiplying the cross-sectional area of the workpiece that needs to be cut by the corresponding unit price, and the unit price will vary according to the number of trimming passes (which directly affects precision and surface finish).
Core Formula
Total Cost = Cutting Area (mm²) × Unit Price (USD/mm² or EUR/mm²)
Key Details & Reference Prices
- The base unit price for general working conditions ranges from 0.004 to 0.014 USD/mm² (subject to regional differences and market fluctuations). For example, the unit price for 1 pass cutting is about 0.004 USD/mm², 2 passes about 0.005 USD/mm², and 4 passes (for high-precision requirements) can reach 0.008 USD/mm².
- There is an unwritten industry rule for workpiece thickness: if the thickness is less than 20mm, it will be calculated as 20mm when computing the cutting area; if it exceeds 20mm, the actual thickness will be used. For workpieces with a thickness exceeding 100mm, an additional 20%-30% fee may be charged due to increased processing difficulty and time.
- Calculation example: For a mold part with a cutting perimeter of 500mm and a thickness of 30mm, using 2 passes cutting (unit price 0.005 USD/mm²), the cutting area is 500mm × 30mm = 15,000 mm², and the total processing cost is 15,000 × 0.005 = 75 USD.
2. Alternative Pricing Method: By Processing Time
For mold workpieces with complex structures, large thicknesses, or irregular shapes (where it is difficult to accurately calculate the cutting area), pricing based on processing time is more appropriate. This method directly links the cost to the actual working hours of the Wire EDM machine.
Core Formula
Total Cost = Processing Time (Hours) × Machine Hour Rate (USD/Hour or EUR/Hour)
Key Details & Reference Rates
- The hourly rate of Wire EDM machines generally ranges from 20 to 45 USD/Hour. In regions with developed mold industries (such as the Yangtze River Delta and Pearl River Delta in China), the hourly rate for general precision processing is about 20-30 USD/Hour, while for high-precision processing (requiring lower processing speed and lower scrap rate), the rate can reach 35-45 USD/Hour.
- For batch processing, the processing time can be estimated by the formula: Processing Time = Processing Cross-Sectional Area / (1200 – 1800) (1500 is usually used as the parameter in most cases). This helps customers quickly estimate the approximate cost before formal processing.
3. Key Factors Affecting Wire EDM Pricing
In addition to the basic pricing methods above, the final processing price will also be adjusted according to the following factors. Understanding these factors can help you optimize your design and reduce unnecessary costs:
| Influencing Factors | Specific Adjustment Rules |
|---|---|
| Material Type | Ordinary steel (such as 45# steel) is priced at the base rate; difficult-to-process materials such as cemented carbide, titanium alloy will increase the price by 30%-50%; tungsten steel may even be priced at twice the base rate due to its high hardness and wear resistance. |
| Workpiece Complexity | Complex structures such as special-shaped holes, narrow slots, acute angles, bevel gears, and upper-lower special-shaped parts may increase the cost by 20%-50%. For example, a 26-degree slope is priced at 1.5 times the base rate, and spur gears are priced at twice the ordinary rate. |
| Precision & Surface Roughness | Ordinary tolerance (±0.02mm) is at the base rate; high precision (±0.005mm) may increase the price by 50%-100%; when the surface roughness Ra value is reduced from 1.6μm to 0.8μm, the price may increase by up to 180% due to the need for more trimming passes. |
| Batch Size | Single-piece production needs to share fixed costs such as programming and mold calibration, so the unit price is higher; for mass production of more than 100 pieces, a discount of 10%-30% can be enjoyed. |
4. Additional Fees to Note
In addition to the basic processing fees, some additional fees may be incurred in specific scenarios. It is recommended that you confirm with the processing factory in advance to avoid subsequent disputes:
- Programming Fee: For complex 3D mold parts, the programming fee for professional 3D Wire EDM programs can range from 70 to 140 USD.
- Consumable Fee: The loss of electrode wire and working fluid is usually about 5%-10% of the material cost, which is sometimes included in the base price or charged separately.
- Rush Order Fee: For urgent orders that require overtime processing or priority scheduling, an additional 30%-50% fee will be charged.
- Minimum Charge: Many manufacturers have a minimum charge standard for small-size templates or parts, usually around 7 USD per piece.
Why Choose Our Wire EDM Processing Service?
As a professional mold processing factory, we adhere to the principle of transparent pricing, precise processing, and sincere service. For every Wire EDM project, we will provide you with a detailed pricing breakdown (including cutting area calculation, processing time estimation, and additional fee explanation) before processing, so that you can clearly understand every cent of your expenditure.
Our team of professional engineers has rich experience in processing various complex mold parts, and can optimize the processing plan according to your needs to help you balance precision requirements and cost control. Whether it is a single-piece customization or mass production, we can provide you with high-quality and cost-effective Wire EDM processing services.
If you have specific Wire EDM processing needs, please feel free to связаться с нами. We will provide you with a free quotation and technical consultation!
