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.
Medical devices demand micron-level precision, biocompatible materials, and surface finishes that affect patient outcomes. EDM Zap has been engineering precision EDM solutions for medical device manufacturers for over 50 years.
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 →Medical device manufacturing operates under a different kind of pressure. The tolerances aren’t just engineering requirements — they’re clinical ones. An implant that’s out of spec by a few microns, a surgical instrument with the wrong surface finish, a catheter component that doesn’t seal correctly — the consequences go beyond quality failure.
EDM is the process of choice for the most demanding medical applications — machining titanium, cobalt chrome, stainless steel, and PEEK to tolerances that conventional processes can’t hold, without the cutting forces or heat that would compromise material integrity or surface quality.
EDM Zap engineers EDM solutions for the full range of medical device applications — from orthopedic implant tooling and surgical instrument components to catheter tip geometries and micro-scale features that require precision beyond what most EDM shops can deliver.
Medical Applications
Bone plates, screws, cutting jigs, and trial components in titanium and cobalt chrome — EDM holds the tolerances and surface finishes required for osseointegration and long-term implant performance.
Precision cutting edges, jaw geometries, and articulating features in hardened stainless steel — EDM delivers the accuracy and repeatability that surgical instrument performance depends on.
Micro-scale tip geometries, laser-cut tubes, and precision internal features in nitinol, stainless, and polymer — EDM machines the features that define catheter performance and patient safety.
Injection mold cavities and inserts for medical plastic components — EDM machines the complex internal geometries and surface textures that conventional toolmaking can’t achieve.
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.
01
Triax Cable and our new control platform
02
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
Sinker EDM in titanium, cobalt chrome, and stainless steel — no cutting force, no heat distortion, and surface finishes controlled to medical device specifications.
Precision machining of features below 0.1mm — slots, holes, internal geometries, and surface textures that define device performance and are unreachable by conventional processes.
Mold cavities, cutting jigs, trial implants, and fixture tooling for medical device manufacturing — held to the same precision standards as the devices they produce.
Multi-head EDM configurations for high-volume medical component production — multiple identical features machined simultaneously to reduce cycle time without compromising precision.
EDM process parameters optimised for medical surface finish requirements — Ra values controlled to specification for osseointegration, tribological performance, and biocompatibility.
Full process documentation and material traceability to support FDA, ISO 13485, and medical device quality management system requirements.
Tell us about your component, your material, and your tolerance requirements. Our engineers will tell you exactly how EDM Zap can help.