EDM, Wire & Sinker

Superb Accuracy, Complex Shapes, Huge Volumetric Envelop

Sinker EDM Process

Various electrodes used for Sinker EDMThe use of EDM means no pressure is applied to the material being machined, the features are burned to their shape rather than abraded. Parts that have been heat treated, or must be heat treated prior to final machining make excellent candidates for the EDM process. Surface finish can be controlled during the EDM process allowing for variable appearances ranging from polished to textured surfaces. 

Sinker EDM (Electrical Discharge Machining) is a process that lends itself to precision machining of features when conventional machining is inappropriate. For instance, if corner radii are not permissible, or need to be held to a tight tolerance, a "positive" shaped electrode can be machined and then "sunk" (burned) into the desired part. Complex features, undercuts, small precise holes, square and blind holes, tight tolerance and fragile features are all examples of operations well suited for sinker EDM.

Wire EDM provides for precision through-hole features to be machined into virtually any conductive material. Applications include extremely small holes (diameters as small as 0.004") or external (perimeter) features that are not suited for traditional machining. Wire EDM also permits inclusion of tapered surfaces on features. Variable angled undercuts and drafts are good examples, and tolerances within .0002" are possible.

Surface finishes typically range between 4 to 64 micro inches for wire and sinker EDM; with the smoother finishes achieved using more precise process parameters.


Injection Molds

Multiple slide mold for medical device companyMold Design, Construction, Modification & Repair

Injection mold for industrial product

Diamond Mold was founded on mold making and continues to take pride in manufacturing superior quality injection molds. Our staff provides unbeatable service and communication from the mold design stage through construction.

Our experience in mold making provides cost-effective design and fabrication of innovative tooling. Use of CNC machining combined with the latest Mitsubishi EDM equipment produces precision tooling for plastic injection molded parts.

Diamond Mold offers a range of tooling from Class 101 molds in hardened steel that will withstand one million part cycles, to less expensive prototype molds in P20 or 7075 aluminum. We specialize in very small and intricate parts that are often molded using MUD inserts (Master Unit Dies). For larger parts with multiple configurations we often design interchangeable inserts than can help reduce up-front tooling costs even further.

ToolingMicro Features via Swiss Turning on an aluminum consumer product

Mandrel for Medical Parts Made by Swiss TurningTools, Fixtures, Jigs, Production Equipment

Whether aerospace fixtures, medical device tooling, or other precision applications, Diamond Mold has the experience and skills to provide precision tooling to meet your needs.

For over 30 years, medical device and aerospace businesses have teamed with Diamond Mold to solve the challenge of producing critical tool and fixture assemblies that must meet specification the first time. We excel in these fields and thrive on satisfying our customers with timely delivery of crucial applications.

CNC & Swiss Turning

Creative Machining for Intricate Designs

Diamond Mold offers CNC milling with the new 2007 Haas VM3 mill whose X, Y, and Z axis travel is optimized for injection mold base dimensions. In addition, we have a Fadal 4020 CNC mill with similar capacity.

Often called a screw machine, Swiss Turning was originally developed for producing parts in the watch industry. Swiss turning is capable of performing multi-axis mill and lathe operations on the same part in one work station. Round stock is continuously fed by the automatic bar feeder through the screw machine's chuck to the cutting heads. Milling, drilling, turning and tapping operations are all achieved in a single programmed sequence using one machine. This process is suited for high volume, slender, or cylindrically shaped production parts, ranging from 0.025" to 1.250" in diameter.


Software Tools for Design and Fabrication

CAD Software tools for Design and Fabrication

Virtual prototype in SolidWorks® of carbon fiber case for biological weapons detection system 

Mastercam for virtual tool path

Mastercam® is shown cutting a virtual tool path for a small mold component

Diamond Mold uses the latest releases of software packages for computer-aided design (CAD), computer-aided manufacturing (CAM), and computer-aided engineering (CAE). These tools enable mechanical design and CNC work in a virtual environment prior to physically machining parts. Additional software used in conjunction with these CAD/CAM packages expands mechanical design capabilities such as COSMOSWorks® finite element analysis (FEA).