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Manufacturing · Software for wire EDM shops

Record every cut, skim pass and spool against the profile it produced.

Wire EDM shops cut hardened D2 and carbide that no milling cutter will touch, and customers judge the result by profile, taper and recast layer. The software for wire EDM shops holds the cut programme, brass spool, skim passes and measured tolerance against each job. Machine hours, fixtures and outside steps such as vacuum hardening follow the same record.

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At a glance

A wire machine runs overnight with nobody beside it. By morning the profile is inside tolerance or the plate is scrap. Punch and die sets, carbide blanking inserts and titanium brackets arrive on brass or zinc-coated wire, mostly as one-offs. Nothing is quick.

Management of a wire EDM shop starts with machine hours, because the cutting time is the product being sold and an idle night is revenue that cannot be recovered. After that come the cut programme, the wire diameter and the skim offsets that decide the surface finish the toolroom will measure. Share your requirements for one die plate.

How the work runs today

A toolroom sends a die plate, a drawing and a request for a quote. You estimate from cut length, plate thickness, grade of tool steel, skim passes, and the time to drill the start hole and clamp the plate in its fixture. The quote also carries wire and filter cost, plus an allowance for hardening before the cut or stress relief after. Pricing runs per machine hour.

At the machine, the operator loads the programme, threads the wire, checks the start hole and runs the rough cut, then the skim passes for size and finish. A wire break means a restart and a note on the job card. The profile is then measured on a coordinate machine against the drawing tolerance in microns. Slugs are kept. The part leaves wrapped with its report.

Where it breaks

What goes wrong for wire EDM shops without a proper system.

Cut time is estimated, never compared

A quote assumes a cutting speed in square millimetres a minute, yet thick tungsten carbide cuts far slower than the quote assumed. Nobody sets the programme time against the actual hours, so the next quote for the same plate repeats the error.

Wire breaks leave no trace

A break at hour six costs a restart and a re-thread through the lower guide. It ends up as a remark on a sticky note, so nobody can see whether 0.25 mm wire in thick tool steel breaks most, or price that risk.

Programmes sit on the machine controller

A cut programme with the offsets and taper angle that worked is stored on one controller. A repeat order on the second machine starts again, with the skim offsets recalculated by hand. Hours vanish.

Fixtures and start holes are forgotten

The plate needs a start hole drilled before it reaches the wire machine, and the clamp set is somewhere else on the shop floor. The job sits first in the queue because nobody is free to drill it, and the machine stands dark.

Profile reports are made from memory

The measured profile is taken on a coordinate machine, and the readings are typed into a report afterwards. Months later a toolroom asks for the report on a punch, and the sheet cannot be found.

What the software does

What we would build for wire EDM shops.

Named the way your team already talks about the work. We start with whichever part the audit shows is costing you most.

Quotation by cut length

Price from cut length, plate thickness, steel grade, skim passes and setup, with wire and resin cost included. Every revision stays linked to the drawing number.

Machine hour booking

Book jobs against each wire machine by table travel and taper limit. Running hours, planned hours and unattended night runs sit together on one board, before a delivery date is promised to a toolroom.

Cut programme library

Keep the programme, offsets, skim settings and wire diameter that worked for a part. Run it again next season and the job opens with the cut that held size, whichever wire machine takes it.

Wire spool and consumable log

Record spool weight per job and tag each break with its cause, so wire cost and break rate can be read by steel grade and thickness.

Start-hole and fixture routing

Route a plate through drilling and clamping before the wire machine, and see which jobs are blocked waiting for those steps.

Profile inspection record

Enter coordinate readings against the drawing tolerance and attach the report, with the inspector’s sign-off, to the job.

Outside process and delivery

Send plates out for vacuum hardening or surface grinding, book them back in, and raise the dispatch note from the count that passed.

Before you talk to a supplier

A requirements checklist for wire EDM shops.

What to cover, which reports to ask for and what to put to every vendor, ready to print or save as a PDF.

Open the checklist
Ready product

A product already built for wire EDM shops.

It is adapted to how your business works before it goes live, and anything your trade needs that it lacks is added then.

Wire EDM Shop Management Software

Quotes by cut length, machine hour booking, cut programmes, wire spools, breaks, CMM profile reports and delivery notes for wire EDM shops.

See the product
Solutions inside

The business modules wire EDM shops use most.

Each one is also available on its own, or inside a system built for you.

Services

The services behind it.

Business Process Automation

Approvals, reminders, follow-ups and reports that run on their own instead of on someone remembering.

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Data Migration and Moving Off Spreadsheets

Data migration and spreadsheet replacement covers auditing existing files, cleaning and deduplicating records, loading them into a new system and reconciling the loaded result against known totals. Both systems then run side by side before cutover. Originals stay untouched.

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IoT and Edge Computing

Machines, meters and sensors feeding the same system your office uses, even when the network drops.

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How it works

How the work runs from Bengaluru for your city.

  1. 1

    The audit, by call

    A screen-share and a look at the sheets, accounting reports and WhatsApp groups your team uses. No travel needed.

  2. 2

    A written proposal

    Scope, what we build first and the cost, agreed in writing before anything starts.

  3. 3

    Build in short rounds

    Working screens shared every few weeks. Your team tests them from your own office.

  4. 4

    Go-live, in person when it helps

    For data migration and training we can come to your city. Travel is agreed in advance.

  5. 5

    Support online

    Fixes, changes and hosting handled remotely by the same team that built it.

Our work

Software we have built and run.

We only name clients whose work is published. These are systems our team designed, built and supports.

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Common questions

Questions wire EDM shops ask before they call.

Can it store cut programmes for repeat jobs?

Yes. The programme file, offsets, skim settings and wire diameter sit under the part number and revision. Next time, the job opens on the last cut that worked.

Does it connect to the wire machine controller?

Not by default. Operators log start, finish and breaks on a terminal. Reading run hours from a controller is a separate integration, scoped with your machine make during implementation.

We only quote one-off dies. Is it still useful?

Yes, because costing stays with the part. One-offs repeat more often than owners expect, and the second quote can start from the actual cut hours of the first.

Can customers’ drawings and revisions be attached?

Yes. Each part holds its drawing and revision history. The operator sees the current print when a job opens. Older prints stay on file.

What happens after I share my requirements?

An engineer reads what you send and replies within one business day. We then look at the software, spreadsheets and WhatsApp groups your business runs on today and write down what works, what slows your team down and what is missing. A demo login, a screen-share or a few screenshots are enough. You get a short written summary ordered by priority, with no obligation to hire us afterwards.

How much will the software cost?

We don’t publish a price, because it depends on what the system has to do. That first review settles the scope, and the cost goes into a written proposal before any work starts.

Related

Related industries.

Category

Part of a wider group.

Talk to us

Tell us how your business runs today.

A few lines on your spreadsheets, software and WhatsApp groups is enough. We reply the same working day.

  • No obligation
  • A reply within one business day
  • Your details stay private

Start with your requirements

Seven short steps that tell us what you need. An engineer reads them before getting in touch.

Share your requirements