Today's Wire EDM machines can cut even exotic metals to as fine as 4 millionths (.000004") of an inch, in increments of 40 millionths (.00004"). The newest machines cut at rates twice that of earlier generations — 25 sq in/hr and more.
The problem is maintaining a quality cut at production line speed. CNC control, premium wire, high flushing rates, and especially using high quality deionized water as the dielectric can make all the difference.
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