EDM ZAP builds a wire EDM machine for metal 3D printing cleanup

EDM ZAP Parts Inc. is developing a wire EDM machine in Montgomery, Illinois, aimed at one of metal additive manufacturing’s most time-consuming steps: separating printed parts from build plates. The company is targeting shops that need safer, faster post-processing for large, heavy metal prints without damaging the parts.

Why it matters: - Post-processing can account for nearly 27% of the cost of an additively manufactured part, based on Wohlers Associates research published in 2021. - Separating metal prints from build plates remains a major bottleneck because the parts are expensive to make and can be damaged during removal. - EDM ZAP is targeting that pain point with a wire EDM machine designed specifically for plate separation, rather than a general-purpose machine adapted for the job.

What happened: - EDM ZAP Parts Inc. said it is developing a wire EDM machine for removing finished metal 3D printed parts from their build plates. - The company is based in Montgomery, Illinois, and has built EDM equipment there since 1971. - Mike Schober said IMTS showed additive manufacturing, especially metal printing, is an important market for EDM ZAP. - Schober said these companies already use wire EDM to separate printed parts from build plates.

The details: - Metal parts often leave laser powder bed fusion machines fused to a metal build plate after days of print time and significant powder use. - Bandsaw cutting requires extra stock for the cut, adds build time and material, and can deform thin walls and difficult alloys. - Wire EDM removes parts without mechanical stress, which is why it has become the preferred method for high-value work. - Many shops still use general-purpose machines built for die and mold work instead of machines sized for oversized plates and very heavy parts. - EDM ZAP says its machine is engineered and assembled in the United States. - Schober said the company’s differentiator is fully customized solutions made 100% in the USA, with machine sizing, cutting requirements, and loading and unloading tailored to the customer’s operation. - The company cites reference jobs involving build plates around 28 by 28 inches, part heights around 30 inches, and part weights up to about 4,400 pounds. - EDM ZAP says those dimensions are reference points, not fixed limits or a standard configuration. - The machine is designed for electrically conductive metals used in additive manufacturing. - EDM ZAP still designs, manufactures, and tests its own EDM power supplies at the Montgomery facility. - The company’s product line includes the Advantage series and the E-Series for the energy sector. - EDM ZAP says it is not a distributor or reseller. - The same technicians who service the equipment also understand the machines at a component level. - EDM ZAP’s broader portfolio includes sinker and custom EDM equipment, classic Elox, ERM, Xermac and Cincinnati platforms, modern CNC systems, and custom-built machines based on part geometry and cycle time targets. - The company says it has delivered 100 custom engineered solutions and services equipment across five continents. - The new machine can be paired with robotic loading, automated fixturing, and full cell controls. - EDM ZAP says those automation systems can be integrated around equipment a customer already owns or around a new build. - The machine is aimed at in-house metal additive manufacturers and metal printing service companies. - Aerospace and defense are the lead markets, followed by automotive, medical, and energy. - EDM ZAP is not disclosing cutting speeds, throughput, or accuracy claims for the machine. - Customer names remain confidential under existing agreements. - The company is asking engineering teams to bring plate sizes, part weights, and materials directly to EDM ZAP for review.

Between the lines: - The move suggests the next competitive edge in metal additive manufacturing may be in post-processing, not just printing speed or part quality. - By designing around plate removal, EDM ZAP is trying to turn a labor-heavy, high-risk step into a more controlled production workflow. - The focus on automation points to demand for repeatable handling of very heavy parts, not just the cutting process itself.

What’s next: - EDM ZAP is working with customers on application-specific machine builds. - Engineering teams interested in the system can bring their part sizes, weights, and material requirements directly to the company. - The company has not yet released performance specifications for the machine.