For nearly 50 years, Jehbco Silicones has been at the forefront of silicone extrusion, amassing an impressive library of over 2,600 extrusion dies and a wealth of knowledge to ensure the delivery of perfect silicone products to their customers. One of the critical elements contributing to our sustained excellence and innovative edge is the use of advanced machining technologies for tool and extrusion die making at Jehbco, such as our Excetek V400G Wire Electrical Discharge Machine (Wire EDM). 

Figure 1. Excetek V400G Wire EDM Machine used for cutting extrusion dies and tooling at Jehbco.

What is Wire EDM? 

Wire EDM is a non-conventional machining process that uses a thin wire as an electrode to cut intricate shapes and fine details in hard materials. The Excetek V400G model employed by Jehbco Silicones stands out due to its precision, reliability, and ability to produce complex geometries with exceptional accuracy. The WEDM process works by generating a series of electrical discharges (sparks) between the wire and the workpiece. These sparks erode the material, creating the desired shape. The wire, typically made of brass or a similar conductive material, does not make physical contact with the workpiece, which allows for precise cutting without the wear and tear associated with traditional machining tools. This technology operates in a submerged environment, which helps to control the temperature and remove debris, further enhancing the precision of the cuts [1][2]. 

Figure 2. Diagram of wire EDM cutting process [3].

Advantages of Wire EDM Over Traditional Machining Methods 

Unparalleled Accuracy: Wire EDM machines, like the Excetek V400G, achieve a level of precision that is difficult to match with traditional machining methods. The accuracy of the Wire EDM process can reach tolerances within microns, making it ideal for producing intricate extrusion dies required in silicone product manufacturing. This precision ensures that the final product adheres to exact specifications, reducing waste and enhancing product quality​ [1][2]. 

Ability to Machine Intricate Geometries: Traditional machining methods often struggle with creating complex shapes and fine details, especially in hard materials. Wire EDM excels in this regard, as it can effortlessly cut intricate geometries, including sharp corners, thin walls, and delicate features. This capability is particularly beneficial for Jehbco Silicones, where the design of extrusion dies often demands intricate patterns to meet specific customer requirements​ [1][4]. 

Figure 3. Extrusion dies with intricate profiles cut using wire EDM.

Material Versatility: Wire EDM machines can cut a wide range of conductive materials, from common metals like steel and aluminium to exotic alloys and hardened tool steels. This versatility allows Jehbco to fabricate extrusion dies and tools from materials best suited to the specific demands of silicone extrusion [2][6]. 

Enhanced Surface Finish: The Wire EDM process produces a high-quality surface finish, often eliminating the need for additional finishing operations. This is crucial for extrusion dies, where a smooth surface ensures consistent flow through the extrusion die and reduces the likelihood of defects such as streaks in the final silicone product [2][6]. 

Automation and Efficiency: Modern Wire EDM machines like the Excetek V400G are equipped with advanced automation features, including CNC controls and automatic wire threading. These features enhance operational efficiency, reduce setup times, and allow for unattended machining. For Jehbco Silicones, this means faster production cycles and the ability to meet tight deadlines without compromising quality​ [2][5]. 

Jehbco’s Expertise and Experience 

With five decades of experience in silicone extrusion, and a library of over 2600 dies and extrusions at Jehbco, there is a wealth of knowledge and data to draw from. This experience and expertise, combined with the precision of our Excetek wire EDM machine, enables Jehbco to fabricate high quality extrusion dies with which to produce the perfect silicone products tailored specifically for our customers. The integration of Wire EDM technology has allowed Jehbco to push the boundaries of what is possible in silicone extrusion, offering innovative solutions and products that set industry standards. 

Overall, the adoption of the Excetek V400G Wire EDM machine at Jehbco Silicones underscores the company’s commitment to precision, innovation, and quality. By leveraging the advantages of Wire EDM, Jehbco continues to lead in the silicone extrusion industry, delivering products that consistently exceed customer expectations. The combination of advanced technology and extensive experience positions Jehbco as a trusted partner for those seeking high-quality silicone extrusion solutions. 

References 

  1. Wire EDM: Guide to EDM Wirecut Machine, Process & Uses – Fine Metalworking.
    https://finemetalworking.com/wire-edm 
  2. Wire EDM: Components, Types, Applications, and Advantages – IQS Directory.
     https://www.iqsdirectory.com/articles/edm/wire-edm.html 
  3. Wire EDM – Manufacturing Guide Sweden
    https://www.manufacturingguide.com/en/wire-edm 
  4. What’s Wire EDM Machining? Techniques, Benefits, and Uses – Rapid Direct.
    https://www.rapiddirect.com/blog/what-is-wire-edm/ 
  5. Wire EDM Explained: Everything You Need to Know – Union Fab.
    https://www.unionfab.com/blog/2023/10/wire-edm 
  6. All About Wire EDM Machining: Definition, Application, and Materials – Xometry.
     https://www.xometry.com/resources/machining/wire-edm-machining/