How do you cut intricate, burr-free shapes into hardened tool steel or titanium with micron-level precision and a mirror-like surface finish? Wire EDM is the non-contact machining technology that makes this possible, using a thin, electrically charged wire to erode material with sparks, regardless of its hardness. This guide provides a deep dive into how Wire EDM works, why it excels at complex geometries, and the factors that influence its superior quality. Explore how techniques like skim passes and precise power control deliver flawless, stress-free parts for high-stakes tooling, aerospace, and medical applications.