Generation of complex micro cavities by micro EDM

Micro EDM, as one of micromachining methods, can be used to machine 3D micro parts, micro die or molds of any conductive materials with high precision. The machined shapes can range from simple micro holes to complex 3D cavities. However, the generation of complex micro 3D shapes requires costly, time consuming and difficult design and fabrication procedures for preparing the complex shaped electrodes. To machine complex 3D shapes correctly using simple shaped electrodes, it is necessary to solve two problems. One is the electrode wear and the other is the application of a CAD/CAM system. In this paper, the recently developed uniform wear method is used to solve the problem of electrode wear and a new approach is proposed to integrate the uniform wear method with the CAD/CAM system. The proposed approach is verified by successfully machining some complex micro cavities.