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.
EDM Zap designs and builds multi-head and multi-lead EDM systems that machine multiple features or cavities simultaneously — cutting cycle times dramatically and maximizing output per shift.
Over five decades of EDM expertise
Equipment serviced worldwide
Custom Engineered Solutions
Standard single-head EDM is a one-at-a-time process. For high-volume production, that’s a constraint. Multi-head and multi-lead configurations break that constraint — running multiple electrodes simultaneously so you’re machining two, four, or more features in the time it previously took to machine one.
EDM Zap engineers multi-head systems from the ground up around your specific part geometry, electrode layout, and production targets. Whether you need dual-head sinker EDM for symmetric die cavities, or a fully custom multi-lead array for a complex aerospace component, we design the machine and the process together.
The result is a step-change in throughput — not incremental improvement. Customers regularly see cycle time reductions of 50–80% per part when moving from single-head to a purpose-built multi-head configuration.
Configuration Range
Two-electrode sinker EDM for symmetric parts — die cavities, mold features, or paired components machined simultaneously with matched power and positioning.
Four, six, or more electrodes in a single setup for maximum throughput. Each lead independently controlled for depth, power, and cycle time — ideal for high-volume aerospace and medical production.
Rotating electrode head configurations for radial features — ideal for components requiring identical geometry at multiple angular positions around a central axis.
No standard configuration fits your part? We engineer a bespoke multi-head setup from scratch. Frame, electrode array, power supply, and process — designed and built as a complete system.
Industries We Serve
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
03
Calibration, repair, and maintenance on demand
04
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
Each head individually positioned and powered to match your part geometry — consistent depth, discharge, and surface finish across every electrode simultaneously.
Each lead runs on its own power channel — allowing different parameters per electrode for parts with varying cavity depths, geometries, or material conditions.
Custom fixture design ensures part location and electrode alignment are repeatable to micron-level accuracy across every production run.
Every multi-head system ships with a factory-matched Advantage series power supply — calibrated to the specific electrode count and process parameters of your application.
We don’t just build the machine — we develop the process. Electrode design, flush strategy, power settings, and cycle sequence engineered alongside the hardware.
Full multi-head cycle testing at our Montgomery, IL facility before shipment — validated against your part geometry and production targets with documented results.
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 →Tell us your part, your current cycle time, and your production targets. We’ll design a multi-head configuration that hits your numbers.
