Meet Us at
This September. Visit Booth 338270 and Discover What’s New.
Meet Us at
This September. Visit Booth 338270 and Discover What’s New.
Aerospace components demand tolerances that leave no room for error. EDM Zap has been machining aerospace-grade parts and engineering purpose-built EDM solutions for aerospace manufacturers since 1971.
Our Products
High-performance generators engineered for stability, speed, and minimal electrode wear.
Learn More →Specialized configurations for simultaneous machining and maximum throughput.
Learn More →Purpose-built systems designed from the ground up for your specific manufacturing challenge.
Learn More →Precision tooling, filtration, and consumables to keep your machines running perfectly.
Learn More →We don't just build the machine we engineer your entire process.
Learn More →Aerospace manufacturing operates at the edge of what’s mechanically possible. Turbine blades, fuel system components, landing gear parts, and structural elements require geometries and surface finishes that conventional machining can’t achieve — and where a single out-of-spec part can ground a program.
EDM is the process of choice for the most demanding aerospace applications — no cutting force, no heat-affected zone, and the ability to hold tolerances in hardened titanium, Inconel, and nickel superalloys that would destroy a conventional tool. EDM Zap has been supplying and engineering EDM solutions for aerospace manufacturers for over 50 years.
From standard sinker EDM equipment to purpose-built multi-head systems for high-volume aerospace production, we engineer the machine and the process around your part — with full calibration, repair, and ongoing support to keep your line running.
Aerospace Applications
Cooling hole drilling, trailing edge profiles, and complex internal geometries in Inconel and nickel superalloys — EDM is the only process capable of holding the tolerances these components demand.
Injector nozzles, valve seats, and flow control components requiring micro-precision geometries in hardened stainless and titanium — machined to aerospace quality standards with full traceability.
High-strength steel and titanium structural components with complex internal features — EDM delivers the accuracy and surface integrity required for flight-critical applications.
Custom EDM tooling, fixtures, and jig components for aerospace assembly and inspection — engineered to the same precision standards as the production parts they support.
Why EDM Zap?
At EDM Zap, we specialise in precision EDM solutions for manufacturers who can't afford downtime. Our engineering team brings decades of hands-on expertise to every project — from standard equipment to fully custom builds.
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Triax Cable and our new control platform
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Built to your exact spec and process
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Calibration, repair, and maintenance on demand
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Serving aerospace, medical, and energy sectors
"EDM Zap delivered a custom solution that reduced our downtime by 40%. The engineering support was exceptional from day one."
"We've relied on EDM Zap for 20 years. Their calibration team is second to none. When they say precision, they mean it."
What's Included
3D cavity machining in hardened titanium, Inconel, and steel — no cutting force, no heat distortion, and tolerances held to the micron across the full production run.
Through-cutting complex 2D and taper profiles in flight-critical materials — exceptional surface finish and dimensional accuracy with no residual stress.
Purpose-built multi-electrode configurations for high-volume aerospace production — multiple identical features machined simultaneously to reduce cycle time and increase throughput.
When your part geometry or production requirement exceeds standard equipment capability, we engineer a machine built specifically for your application — designed, built, and validated in-house.
Regular calibration and preventive maintenance to keep your EDM equipment operating within aerospace tolerances — on-site across North America or in-house at our Montgomery, IL facility.
Full process documentation, calibration records, and material traceability to support your quality management system and aerospace certification requirements.
Tell us about your part, your material, and your tolerance requirements. Our engineers will tell you exactly how EDM Zap can help.