How to choose your molybdenum wire EDM machine

Choosing a wire-cut EDM machine is not just about comparing prices and sizes. There are technical factors that directly influence the final result, productivity, and the cost per part. Among these factors, some points weigh heavily: motion resolution, cutting accuracy, surface finish, and the real quality of the process.

Outdated machines have limited software. A clear example is the Z-axis control system, still found in so-called “new” machines. In the past, they used manual scales or simple motorized systems that only moved the head up or down — some even had a second control panel with exclusive buttons to move the Z axis, completely isolated from the machine’s software. There was no communication, no electronic reading, and no real precision for angled cuts. The operator relied on eyesight, a ruler, and experience to get it right. Even today, models with this outdated concept can still be found being sold on the market.

The result was time-consuming adjustments, complete dependency on the operator’s skill, and difficulty performing angled cuts. What should be simple became a trial-and-error process, manual calculations, and inevitable variations from one cut to another.

In modern machines, that no longer makes sense. The Z axis must communicate with the software, follow parameters, and repeat positions with precision. This is exactly what PROMILL offers: a fully electronic Z integrated into the CNC. The operator enters a single parameter, and the machine calculates, positions, and repeats the ideal height for straight cuts, angled cuts, or dual-profile cuts. No physical effort, no manual adjustment, and no wasted time.

Another decisive point is motion resolution. It determines the stability of the feed, the smoothness of the path, and the final cutting quality. PROMILL machines work with 0.001 mm motion resolution and 0.01 mm real cutting resolution, ensuring stability, consistency, and repeatability even in long, delicate geometries or tight-tolerance applications.

It is also important to evaluate generator consumption. The lower the kVA or kW value, the lower the daily operating cost. In this regard, PROMILL provides a clear advantage: it consumes up to three times less energy than many competing machines, resulting in direct savings on electricity bills and a lower cost per part at the end of the month.

Finally, cutting efficiency must be considered. Most machines on the market operate between 150 and 180 mm²/min. PROMILL, however, delivers much higher performance: the E Series reaches 220 mm²/min, and the U Series reaches 300 mm²/min. In practice, this places the E Series between 22% and 46% above market average, while the U Series can be 66% to 100% faster, depending on the reference baseline used.

In the end, the choice comes down to this: less manual adjustment, more precision, more repeatability, lower energy consumption, and higher real cutting speed. This is the combination that defines a good molybdenum wire EDM machine — and it is exactly the combination that PROMILL delivers.