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Precision EDM for Forging Die Tooling.
Forging dies take the most punishment of any tooling in manufacturing. EDM Zap machines the complex cavity geometry, draft angles, and flash land profiles in fully hardened H13 and hot work tool steel — the features that define forging quality and die life.
Our Products
Industry-Leading EDM Equipment
EDM Power Supplies
High-performance generators engineered for stability, speed, and minimal electrode wear.
Learn More →Multi-Head / Multi-Lead
Specialized configurations for simultaneous machining and maximum throughput.
Learn More →Custom EDM Machines
Purpose-built systems designed from the ground up for your specific manufacturing challenge.
Learn More →Components & Accessories
Precision tooling, filtration, and consumables to keep your machines running perfectly.
Learn More →Engineering & Process Acceleration
We don't just build the machine we engineer your entire process.
Learn More →Forging Applications
Die Cavity to Flash Land. Every Feature EDM Can Hold.
Forging Die Cavities
Finish EDM of impression die cavities in H13 and hot work tool steel — draft angles, fillet radii, and surface finish held to the tolerances that forging quality and die life depend on.
Die Insert & Pad EDM
Precision sinker EDM of forging die inserts, wear pads, and replaceable cavity sections — machined to exact dimensional match for drop-in replacement without rework.
Flash Land & Trim Die
EDM machining of flash land profiles, trim die cutting edges, and parting line geometry — the features that control flash thickness and forging dimensional accuracy.
Die Rework & Repair
EDM rework of worn forging dies — restoring cavity geometry, correcting wear patterns, and extending die life without re-machining from a solid block.
The Tooling That Shapes Metal. We Machine It.
Forging dies operate under extreme conditions — repeated high-pressure impact, thermal cycling, and abrasive contact with hot metal. The geometry of the die cavity directly determines the shape, dimensional accuracy, and surface quality of every forged part it produces. Getting that geometry right, in fully hardened H13, matters enormously.
EDM is the standard process for forging die cavity work. Conventional machining can rough the cavity, but EDM finishes it — holding the draft angles, fillet radii, and surface finish that define part quality and die longevity. EDM also allows rework of worn dies without re-machining from scratch, extending die life and reducing tooling cost.
EDM Zap supplies and services EDM equipment for in-house forging die shops, and can machine die cavities and inserts for forging operations that don’t have EDM capability in-house. We understand the tolerances, materials, and pressures that forging toolmakers work under.
Why EDM Zap?
Engineering expertise you can rely on.
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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Proprietary Technology
Triax Cable and our new control platform
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Custom Engineering
Built to your exact spec and process
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Responsive Support
Calibration, repair, and maintenance on demand
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Trusted by Industry
Serving aerospace, medical, and energy sectors
Trusted by Industry Leaders
"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
Forging Die EDM. From New to Rework.
Cavity Finish EDM
Finish sinker EDM of forging die impressions in fully hardened H13 — holding draft angles, fillet radii, and surface finish to the tolerances that define part geometry and die life.
Hot Work Tool Steel EDM
EDM in H13, H21, H22, and other hot work tool steels at full hardness — no distortion, no re-hardening required, and full dimensional control throughout.
Insert & Wear Pad Machining
Precision EDM of replaceable die inserts and wear pads — machined to exact dimensions for drop-in replacement, extending overall die assembly life and reducing downtime.
Die Rework & Life Extension
EDM rework of worn forging dies — restoring cavity geometry and correcting wear patterns to extend die life and defer the cost of a new die block.
Custom Electrode Manufacturing
Graphite and copper electrodes manufactured to your die cavity geometry — precision machined for accurate dimensional transfer and optimal surface finish in H13 and hot work steel.
EDM Equipment for Die Shops
Supply, calibration, and repair of sinker EDM equipment for in-house forging die shops — EDM Zap Advantage systems and legacy platforms supported across North America.
Need EDM for Your Forging Die Tooling?
Tell us about your die, your material, and your geometry requirements. Our engineers will specify the right EDM process to hit your tolerances and extend your die life.