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.
Complex cavities, sharp internal corners, and fine surface textures in fully hardened tool steel — EDM Zap has been machining mold tooling to the tolerances that injection molding demands 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 →Injection mold tooling is where EDM earns its place. Sharp internal corners with zero radius. Fine surface textures in hardened P20 and H13. Complex 3D cavity geometries that a milling cutter can’t reach. EDM doesn’t just do these things — it does them in material that’s already hardened, eliminating post-machining distortion and the need for additional heat treatment cycles.
EDM Zap has been machining mold cavities, cores, inserts, and ejector systems for plastic injection, die casting, and rubber molding toolmakers for over 50 years. We understand the tolerances, the surface finish requirements, and the cycle time pressures that mold shops operate under.
From standard sinker EDM for cavity work to multi-axis EDM for precision insert profiles, we supply the equipment, perform the machining, and engineer custom solutions for the tooling challenges that standard approaches can’t solve.
Moldmaking Applications
3D cavity and core machining in P20, H13, and S7 tool steel — sharp internal corners, complex geometry, and fine surface textures in fully hardened material with no post-machining distortion.
Complex cavity geometry in H13 and hot work tool steel for aluminum, zinc, and magnesium die casting — EDM machines the features that withstand the thermal cycling of high-pressure die casting.
Multi-axis EDM cutting of precision insert profiles for interchangeable mold inserts — exact dimensional match to the cavity, tight tolerances, and excellent surface finish in fully hardened steel.
EDM machining of complex ejector pin pockets, lifter channels, and conformal cooling geometries — features that improve mold performance and part quality that conventional machining can’t reach.
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
Ram EDM for 3D mold cavity geometry in fully hardened tool steel — sharp corners, fine Ra surface finish, and complex undercut features that milling can’t achieve.
Precision multi-axis EDM cutting of mold insert profiles, parting line features, and through-cavity geometry — dimensional accuracy to ±0.001" in hardened P20, H13, and D2.
Fine-finish EDM for mold texture — controlled Ra surface finish from 16 to 125 microinches without polishing, directly in hardened tool steel.
EDM machining of complex core pins, lifter rails, and side action geometry — features with internal radii, draft angles, and tight dimensional requirements in hardened tool steel.
Supply, calibration, and repair of sinker EDM equipment for in-house mold shops — Elox, ERM, Xermac, Cincinnati, and EDM Zap Advantage systems supported.
Graphite, copper, and brass electrodes manufactured to your cavity geometry — precision machined for accurate dimensional transfer and optimal surface finish in your specific tool steel.
Tell us about your cavity, your material, and your surface finish requirements. Our engineers will specify the right EDM process for your tooling challenge.